Scanner-Guided Linear Laser Beam Shaping for Faster Workpiece Processing
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Solution Overview
Problem
Existing laser beam processing methods are limited by the rapid movement requirements of scanner optical units, which restrict processing speed due to the high acceleration and braking demands on mirrors, leading to system limitations in processing speed and efficiency.
Innovation Solution
The method involves guiding a laser beam with a scanner optical unit, shaping the beam to have a linear or rectangular cross-section with an aspect ratio of more than 2, allowing for slower movement in the scan transverse direction while maintaining efficient processing by using a galvanometer scanner and asymmetric collimation to balance movement speeds and optimize processing area coverage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the scanner optical unit scans rapidly in one direction to process larger workpiece areas, then the processing speed and productivity are improved, but the mirror drive reaches its loading limits and the system becomes constrained by acceleration and braking demands
Solution Approach 1:
The patent applies asymmetric beam shaping by transforming the circular laser beam cross-section into an elliptical or linear shape with a specific aspect ratio (long side to short side greater than 2). This asymmetric transformation allows the beam to cover a larger area in the scan direction without requiring proportional increases in scan speed, thereby reducing the dynamic loading on mirror drives while maintaining or improving productivity.
Solution Approach 2:
The patent changes the geometric parameters of the laser beam by applying asymmetric collimation and shaping optics to achieve a controlled aspect ratio. This parameter change enables the beam to deliver the same processing power over a larger area with reduced scan velocity requirements, directly addressing the mirror drive loading constraint while preserving productivity.
2Productivity
If the scanner optical unit moves quickly to cover larger areas, then the processing efficiency is improved, but the stress on the scanner drives increases and limits the maximum processing speed
Solution Approach 1:
By transforming the symmetric circular beam into an asymmetric elongated beam with aspect ratio greater than 2, the patent enables larger area coverage per scan position. This reduces the number of scan positions required and lowers the peak scan speeds needed, thereby decreasing stress on scanner drives while maintaining processing efficiency.
Solution Approach 2:
The patent extends the beam dimension in one direction (creating a linear or rectangular cross-section) to compensate for reduced scan speed. This dimensional change allows the system to cover the same area with slower, less stressful scanner movements, reducing drive stress while preserving productivity.
3Manufacturing precision
If the laser beam is focused to a small spot for high power density, then the processing quality is improved, but the scanning speed must be increased rapidly which limits the overall system speed
Solution Approach 1:
The patent creates an asymmetric beam profile with high power density maintained along the long dimension while extending the beam width in the scan direction. This allows slower scan speeds without sacrificing processing quality, as the elongated beam maintains sufficient energy concentration along its length while covering more area per position.
Solution Approach 2:
By changing the beam parameters through asymmetric shaping to achieve a controlled aspect ratio, the patent decouples the relationship between spot size and scan speed. The transformed beam parameters enable lower scan speeds while maintaining the power density necessary for high-quality processing.
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 approach enables the full power of the laser beam to be utilized effectively, allowing for faster processing of larger workpiece areas with reduced stress on the scanner optical unit drives, achieving efficient processing even at lower scan speeds and higher pulse rates, while maintaining thorough coverage and temperature control.
Implementation Method 1
processing a workpiece with a laser beam
Implementation Method 2
guiding the laser beam by a scanner optical unit of an optical system
Data Source
AI summary
A method for processing a workpiece with a laser beam includes guiding the laser beam by a scanner optical unit of an optical system. The laser beam has a linear cross section with an aspect ratio of a long side to a short side of more than 2 when impinging on the workpiece.