Polygon Mirror Laser Perforation for Faster Aerostructure Scanning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing laser/scanner perforation systems for aerostructures are slow due to the limitations of galvo-based x-y scanners, which hinder efficient perforation creation in aerostructure production.
Innovation Solution
A perforation system utilizing a movable base, a laser, and a first polygon mirror, where the laser is fixed and the polygon mirror is rotatably mounted, with a controller to position the base and operate the laser and mirror to create perforations across a substrate, enhancing speed and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a galvo-based x-y scanner is used for laser perforation, then control of beam direction in two planes is achieved, but the processing speed becomes much slower than desired for aerostructure production
Solution Approach 1:
The patent replaces the mechanical galvo-based x-y scanner system with a polygon mirror system that uses rotational motion to deflect the laser beam. The polygon mirror rotates to sweep the laser across the substrate in one direction while the substrate itself moves in the opposite direction, creating a scanning effect without requiring two galvanometer mirrors. This substitution of mechanical scanning with rotational polygon mirror technology significantly increases processing speed and productivity for laser perforation of aerostructures.
2Ease of operation
If a standard two galvanometer mirror system is used, then flexible pointing control in two planes is achieved, but the process becomes relatively slow for creating perforations
Solution Approach 1:
The patent introduces a new dimensional approach by moving the substrate in one dimension (along the scan direction) while the polygon mirror provides beam deflection in the perpendicular dimension. This dimensional separation allows the system to achieve two-plane scanning capability without the speed limitations of dual galvanometer systems. The substrate motion combined with polygon mirror rotation creates effective two-dimensional beam control at much higher speeds, resolving the contradiction between pointing flexibility and processing speed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration significantly reduces the time required to form perforations compared to standard systems, improving efficiency as the size of the substrate increases and enabling precise control over perforation layout and depth.
Implementation Method 1
a laser, mounted in a fixed position on the movable base
Implementation Method 2
the first polygon mirror is rotatably mounted on the movable base... to rotate the first polygon mirror to define a plurality of perforations
Data Source
Figure 1A~1C
Figure 1D~1E
Figure 2A
AI summary
Various arrangements are disclosed for forming one or more perforations on a substrate surface (22) using a laser system, at least one rotating polygon mirror (130), and at least one other movable mirror (150). A rotating polygon mirror (130) is used to define a plurality of perforations in a row set or band (30) on a substrate surface (22) by incrementing, e.g., moving, a first mirror (150) between a plurality of fixed, e.g., pointing, positions. A second rotating polygon mirror (180) may be used to define a plurality of perforations in a row set or band (30) on a substrate surface (22), where the first and second polygon mirrors (130, 180) are used to define an extent of a given perforation (12) in two dimensions on the substrate (20).