Relay Optics and Beam Scanning for Hard-to-Reach Laser Machining
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Solution Overview
Problem
Laser processing of hard-to-access workpieces with high thermal and electrical conductivity materials is challenging due to high reflection issues and process instabilities caused by limited focal length and space constraints, leading to reduced beam quality and increased space occupation for process monitoring and material feeding.
Innovation Solution
A device utilizing a relay optical system with multiple focal lengths and a beam scanner to achieve a small focus diameter and large scanning field, allowing for effective and stable high-power laser processing with minimal lateral space occupation, using a relay optical system with two relay optical groups and a focusing unit to create an intermediate focus and defocus the beam for precise focusing on the workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a short focal length is used to reduce focus diameter and improve laser process stability, then manufacturing precision and process stability are improved, but the working distance and accessibility to the workpiece are reduced
Solution Approach 1:
The optical system is divided into multiple groups (first relay optical group, second relay optical group, and focusing unit) with different functions. The relay optical groups handle beam transmission and expansion while the focusing unit provides precise focusing, allowing each component to be optimized independently for its specific function rather than compromising overall performance.
Solution Approach 2:
The patent uses a relay optical system that expands the beam in the lateral dimension while maintaining a long working distance in the axial dimension. This dimensional separation allows the system to achieve both large working distance and small focus diameter by manipulating beam parameters in different spatial dimensions.
2Ease of operation
If a long focal length is used to increase working distance and accessibility, then ease of operation is improved, but focus diameter increases leading to process instability
Solution Approach 1:
The optical system is divided into multiple groups (first relay optical group, second relay optical group, and focusing unit) with different functions. The relay optical groups handle beam transmission and expansion while the focusing unit provides precise focusing, allowing each component to be optimized independently for its specific function rather than compromising overall performance.
Solution Approach 2:
The relay optical groups act as intermediaries between the laser source and the workpiece. They transmit and condition the laser beam over long distances while the focusing unit serves as the final intermediary that delivers precise focusing to the workpiece, enabling both long working distance and small focus diameter.
3Area of stationary object
If space-saving focusing lenses are used to reduce lateral space occupation, then device complexity is reduced, but cooling surface area is reduced leading to thermal instability
Solution Approach 1:
The optical system is divided into multiple groups (first relay optical group, second relay optical group, and focusing unit) with different functions. The relay optical groups handle beam transmission and expansion while the focusing unit provides precise focusing, allowing each component to be optimized independently for its specific function rather than compromising overall performance.
Solution Approach 2:
Different parts of the optical system have different optical qualities and functions. The relay optical groups use lenses optimized for beam transmission and expansion with adequate cooling, while the focusing unit uses a specialized lens optimized for precise focusing. Each component has local quality optimized for its specific function, allowing the system to achieve both compact size and thermal stability.
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
Enables reliable and stable high-power laser processing with minimal space occupation, allowing for flexible working on large surfaces and internal structures, and integrated process monitoring and material feeding, while maintaining optical component stability and preventing damage from high power densities.
Implementation Method 1
the first relay optical group being adapted to focus the imaging optical path in an intermediate focus located separately from the first and the second relay optical groups between the first and the second relay optical group
Implementation Method 2
a beam scanner arranged before the first relay optical group seen in the propagation direction of the imaging optical path, which scanner is provided both as an entrance pupil for the imaging optical path entering the first relay optical group and for at least deflecting the imaging optical path in relation to the optical axis
Implementation Method 3
the focusing unit being adapted to focus the imaging optical path in a focus of the device on a focus plane for processing the workpiece
Data Source
AI summary
A device is provided for processing hard-to-access workpieces by means of an imaging optical path as well as a corresponding method for laser processing by means of this device, comprising a relay optical system with an optical axis passing through the relay optical system and a focusing unit arranged behind the same seen in the optical axis in the propagation direction of the imaging optical path, with a plurality of optical elements for generating a third focal length, as well as a beam scanner arranged before the first relay optical group seen in the propagation direction of the imaging optical path, which scanner is provided both as an entrance pupil for the imaging optical path entering the first relay optical group and at least for deflecting the imaging optical path in relation to the optical axis.