Resonant Scanner Laser Drilling System
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current laser processing systems for drilling holes in printed circuit boards are limited by the response rate of positioning systems, particularly the limited rotation motors, which constrain speed due to heat dissipation proportional to the fifth power of speed, leading to inefficient drilling of multiple holes.
Innovation Solution
A laser processing system utilizing a combination of a fast resonant scanner and a slower limited rotation motor, where the fast scanner is positioned before a beam expander to achieve higher speeds with lower power consumption, and the system includes a beam expander and focusing optics to maintain a relatively stationary laser spot at the target location, allowing for faster drilling of closely spaced holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the bandwidth of limited rotation motors is increased to improve positioning speed, then drilling speed is improved, but power dissipation increases proportionally to the fifth power of speed
Solution Approach 1:
The positioning function is divided into two separate scanning units: a first scanning unit (galvo scanner) for precise positioning and a second scanning unit (resonant scanner) for high-speed scanning. This segmentation allows each unit to operate at optimized speeds without requiring the limited rotation motor to achieve both precision and high speed simultaneously, thereby reducing power dissipation while maintaining positioning capability.
Solution Approach 2:
The resonant scanner acts as an intermediary between the galvo scanner and the workpiece. The galvo scanner positions the beam at the desired location, and the resonant scanner provides high-speed scanning motion around that position. This intermediary approach enables fast scanning without requiring the limited rotation motor to operate at high speeds, reducing power consumption.
2Measurement precision
If the settling performance of limited rotation motors is improved by increasing bandwidth, then positioning accuracy is improved, but the stepping rate is limited by motor efficiency and heat dissipation
Solution Approach 1:
The scanning system is segmented into two functional units: the galvo scanner handles precise positioning for accurate hole placement, while the resonant scanner handles high-speed scanning for improved throughput. This division allows the galvo to operate at lower speeds with high precision, and the resonant scanner to provide fast scanning motion, achieving both accuracy and productivity simultaneously.
Solution Approach 2:
The resonant scanner operates at its resonant frequency to provide dynamic high-speed scanning motion. By utilizing resonance, the system achieves fast scanning speeds without requiring excessive power input, thereby improving productivity while maintaining the positioning accuracy provided by the galvo scanner.
3Device complexity
If a single scanner is used for both positioning and scanning, then device complexity is reduced, but the response rate limits the drilling speed of multiple holes
Solution Approach 1:
The scanning function is divided into two separate units: a galvo scanner for positioning and a resonant scanner for high-speed scanning. Although this increases device complexity compared to a single scanner, it enables the system to achieve both precise positioning and high drilling speeds by allowing each unit to operate at its optimal performance level.
Solution Approach 2:
The system combines the positioning capability of the galvo scanner with the high-speed scanning capability of the resonant scanner. By merging these two scanning units into a coordinated system, the invention achieves response rates fast enough for high-speed multi-hole drilling while maintaining positioning accuracy, overcoming the limitations of a single scanner.
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 enables faster drilling speeds with lower power consumption, relaxed accuracy requirements, and easier calibration, allowing for efficient processing of clusters of holes with improved throughput and reduced manufacturing expenses.
Implementation Method 1
employing a resonant scanner in an X-Y high speed drilling system
Implementation Method 2
The beam expander is for receiving the laser output and for modifying a beam diameter of the laser output
Implementation Method 3
The focusing optics is for focusing the modified laser output toward the target location
Data Source
AI summary
A laser processing system is disclosed for providing a relatively small velocity of a laser beam at target location while at least one scanner scans at a relatively larger velocity. The system includes a laser source, a first scanning unit, a beam expander, a second scanning unit and focusing optics. The laser source is for providing a pulsed laser output having at least one beam with a beam dimension. The first scanning unit is for scanning the laser output in a first direction along a first axis at the target location. The beam expander is for receiving the laser output and for modifying a beam diameter of the laser output and providing a modified laser output. The second scanning unit is for scanning the modified laser output from the beam expander in a second direction along the first axis at the target location. The second direction is substantially opposite to the first direction along the first axis such that a net velocity of the modified laser output along the first axis at the target location may be made to be effectively zero during a laser pulse. The focusing optics is for focusing the modified laser output toward the target location.