Risley Prism Laser Ablation Head for Fragile-Area Beam Steering
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Solution Overview
Problem
Current laser ablation tools face challenges in restricted areas like gas turbine engines due to fragility and limited control of MEMS systems and the inability to make on-the-fly adjustments with fixed diffractive optical elements, leading to insufficient beam intensity and reduced lifespan.
Innovation Solution
A laser ablation tool utilizing a pair of Risley prisms connected to a rotation mechanism within a housing, allowing for controlled deflection and shaping of the laser beam through coordinated motor-driven rotation, coupled with a borescope or compliant robot for access to difficult areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If MEMS system is used to manipulate laser beam, then beam control capability is improved, but device fragility and reliability deteriorate
Solution Approach 1:
The patent replaces the electrical MEMS actuation system with a mechanical rotation mechanism driven by motors. This substitution eliminates the fragile electrical fingers and actuation electronics, providing a more robust mechanical system that can withstand the harsh environment of gas turbine engines while maintaining beam manipulation capability through physical rotation of the diffractive optical element.
Solution Approach 2:
The patent employs a simpler, more replaceable mechanical rotation mechanism compared to complex MEMS systems. The mechanical components can be easily replaced if worn or damaged, and the overall system design prioritizes ease of replacement over long-term durability, suitable for the harsh operating conditions where the tool may need frequent maintenance.
2Manufacturing precision
If fixed diffractive optical element is used, then beam shaping capability is improved, but adaptability and on-the-fly adjustment capability deteriorate
Solution Approach 1:
The patent transforms the static fixed diffractive optical element into a dynamic component by mounting it on a motor-driven rotation mechanism. This allows the element to be rotated to different angular positions, enabling on-the-fly adjustment of beam shaping characteristics and adaptation to different damage sizes and shapes, while maintaining the precise beam shaping capability of the diffractive optical element.
Solution Approach 2:
The patent makes the diffractive optical element multi-functional by enabling its rotation to different positions. A single element can perform multiple beam shaping functions by being oriented at different angles, eliminating the need for multiple fixed elements and providing universal adaptability for various ablation requirements.
3Manufacturing precision
If fixed diffractive optical element is used, then beam profile control is improved, but beam intensity deteriorates due to spreading
Solution Approach 1:
By enabling dynamic rotation of the diffractive optical element, the system can optimize beam concentration by selecting appropriate angular positions. The rotation mechanism allows the element to be oriented to focus beam energy more effectively on the target, reducing unwanted spreading and maintaining higher beam intensity while still achieving precise beam profile control.
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 robust, controlled, and adaptable laser ablation with improved beam intensity and flexibility, allowing for precise ablation patterns and extended tool lifespan by using Risley prisms to direct and focus the laser beam effectively.
Implementation Method 1
the at least two Risley prisms can be rotate relative to each other and the housing so as to deflect the beam
Implementation Method 2
Laser ablation uses a beam from a laser to heat up and vaporise a section of the component
Data Source
AI summary
A laser ablation tool comprising a laser source which produces a beam heaving a beam path and an ablation head, the ablation head comprising a housing which on each side of the beam path is separated into a first and second portion, and at least a first Risley prism and a second Risley prism connected to the first and second portions of the housing the first and second Risley prisms being connected to a rotation mechanism, so that the two Risley prisms can be moved relative to each other and the housing so as to deflect the beam.