Rotating Energy Beam Surface Processing for Precision Trimming
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Solution Overview
Problem
Current surface polishing methods, such as magnetorheological finishing (MRF) and ion beam figuring (IBF), face challenges in achieving high precision and efficiency while being costly and unsuitable for mass production due to high equipment costs, long processing times, and lack of integrated topography detection systems.
Innovation Solution
A surface processing equipment and method utilizing a composite machining sequence of beam-shaped and ring-shaped energy beams, integrated with a measuring device, gas source, and multi-axis platform, allowing for non-contact surface processing and adjustment of energy beam parameters based on real-time surface form information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If ion beam figuring (IBF) is used to achieve high precision surface processing, then manufacturing precision is improved to atomic scale (0.02λ), but processing time increases significantly and equipment cost increases
Solution Approach 1:
The patent changes the fundamental parameters of the processing method by using plasma-based energy beam instead of traditional ion beam, operating at atmospheric pressure instead of vacuum, and using composite machining sequences with different beam shapes to achieve both high precision and reduced processing time
Solution Approach 2:
The patent segments the processing into multiple sequences with different beam shapes (circular, linear, rectangular) and control modes (continuous scanning, intermittent scanning, dwelling), allowing optimization of processing time while maintaining precision through coordinated multi-axis movement
2Productivity
If magnetorheological finishing (MRF) is used for surface polishing, then production efficiency is improved compared to IBF, but equipment construction cost increases dozens of times compared to traditional polishing
Solution Approach 1:
The patent replaces complex mechanical MRF systems with a plasma-based energy beam system that uses electromagnetic fields and gas flow control, significantly simplifying the equipment structure while maintaining high production efficiency through non-contact processing
Solution Approach 2:
The patent changes the processing medium from magnetic particles in liquid to plasma state gas, and operates at atmospheric pressure instead of requiring complex vacuum systems, thereby reducing equipment complexity and cost while maintaining productivity
3Manufacturing precision
If MRF uses micron-scale high magnetic permeability particles in polishing liquid, then polishing effectiveness is improved, but the particles are prone to rust due to oxidation making the polishing liquid unrecyclable
Solution Approach 1:
The patent changes the state of the processing medium from liquid with solid particles to plasma state gas, eliminating the oxidation and rusting problems entirely while maintaining effective material removal through plasma chemistry and physical sputtering
Solution Approach 2:
The patent converts the harmful effect of particle oxidation into a beneficial plasma state where the gas molecules are ionized and excited, providing both cleaning and processing functions without the drawbacks of particle-based systems
4Device complexity
If traditional full-area polishing is used, then equipment cost is reduced compared to MRF and IBF, but manufacturing precision and ability to achieve local trimming are insufficient
Solution Approach 1:
The patent applies local quality by using a focused energy beam that can be precisely positioned and controlled to process only specific local areas of the workpiece, enabling local trimming and high-precision modifications without requiring complex MRF or IBF equipment
Solution Approach 2:
The patent uses dynamic multi-axis platform control to move the energy beam across the workpiece surface, allowing flexible adaptation to different processing areas and patterns while maintaining simple equipment structure and low cost
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 precise and efficient surface finishing with reduced irregularity, capable of operating at standard atmospheric pressure, and adaptable for various workpieces, improving processing efficiency and reducing costs.
Implementation Method 1
The rotating sleeve is adapted to rotate along the rotation axis and provide the energy beam from one of the plurality of openings to the workpiece for processing
Implementation Method 2
The gas source is adapted to provide a processing gas
Implementation Method 3
The measuring device is adapted to measure a workpiece to obtain surface form information
Implementation Method 4
use the energy beam to etch and remove the surface of the lens to achieve the object of high precision and reduce irregularity
Data Source
AI summary
A surface processing equipment using an energy beam including a measuring device, a gas source, an energy beam supply device, a multi-axis platform, and a processing device is provided. The measuring device measures a workpiece to obtain surface form information. The energy beam supply device receives a processing gas to form an energy beam. The energy beam supply device includes a rotating sleeve. Openings are on a bottom surface of the rotating sleeve. The rotating sleeve rotates along a rotation axis and supplies the energy beam from one of the openings to the workpiece. The processing device controls the gas source, the energy beam supply device, and the multi-axis platform according to the surface form information. Distances from each opening to the rotation axis are all different. The energy beam is formed into a beam shape or rings having different radii via a rotation of the energy beam supply device.