Rotating Laser Beam Tool for Fast Cylinder Bore Roughening
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Solution Overview
Problem
Current methods for roughening cylinder bore surfaces in internal combustion engines are not suitable for fully automated and reliable mass production, requiring significant time and lacking efficient machining solutions.
Innovation Solution
A compact laser beam tool design with a rotationally fixed collimator and a focusing lens that rotates with the spindle, allowing for precise and efficient surface roughening, combined with a masking element, cooling system, and extraction apparatus to ensure high-quality and safe machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional laser roughening setup is used, then the surface can be roughened, but the machining time is too long for mass production
Solution Approach 1:
The patent applies dynamics by making the beam tool rotate together with the spindle at high speeds (typically 100-10000 rpm), transforming the static laser processing setup into a dynamic one. This rotational motion enables continuous processing of the entire cylinder bore surface without repositioning, dramatically reducing machining time from minutes to seconds while maintaining processing quality
Solution Approach 2:
The patent implements continuity of useful action by maintaining constant laser beam application during the rotational motion. The laser beam continuously processes the surface as the beam tool rotates with the spindle, eliminating idle time between processing segments and enabling uninterrupted material modification throughout the entire bore surface
2Device complexity
If the collimator rotates with the spindle, then the beam tool becomes compact, but connecting the collimator to the beam source becomes complex
Solution Approach 1:
The patent uses an intermediary approach by introducing a non-rotating collar or coupling mechanism between the rotating collimator and the stationary beam source. This intermediary component transfers the laser beam from the stationary source to the rotating collimator without requiring the beam source itself to rotate, simplifying both the connection and the overall structure
Solution Approach 2:
The patent applies segmentation by separating the rotating components (collimator, focusing lens, beam tool) from the stationary components (beam source, support structure). This segmentation allows the collimator to be independently mounted on the rotating spindle while the beam source remains stationary, simplifying the connection interface and reducing manufacturing complexity
3Manufacturing precision
If the focusing lens is stationary, then the beam tool structure is simpler, but the laser beam quality deteriorates
Solution Approach 1:
The patent merges the focusing lens with the rotating beam tool structure, combining the optical focusing function with the rotational motion system. This integration ensures that the focusing lens maintains precise alignment with the laser beam axis during rotation, preserving beam quality while eliminating the need for complex stationary mounting mechanisms
4Object-affected harmful factors
If the laser beam is exposed during machining, then the process is simple, but safety risks increase and contamination occurs
Solution Approach 1:
The patent employs a transparent protective window or film at the beam tool exit that allows the laser beam to pass through while preventing contamination and protecting against safety risks. This thin film or window acts as a barrier that maintains the sealed environment while permitting optical transmission, reducing both safety hazards and contamination without requiring complex sealing mechanisms
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 rapid and reliable roughening of cylinder bore surfaces in under one minute, improving machining quality and productivity while minimizing risk and environmental contamination.
Implementation Method 1
roughening by means of laser radiation
Implementation Method 2
the collimator, which parallelizes the divergent light beam
Implementation Method 3
The focusing lens of the focal length f, which rotates at the rotational speed of the spindle and focuses the beam on the surface of the bore
Implementation Method 4
If necessary, the collimator can be cooled by air or by another gaseous or liquid fluid
Data Source
AI summary
The invention relates to a device for roughening cylinder bores using a beam tool and offering a very high level of process reliability even for a large quantity.