Variable Optical Path Laser Beam Delivery via Relay Imaging
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Solution Overview
Problem
Current high energy laser peening systems are limited by the need to move large work pieces, which increases costs and engineering complexity, and conventional beam delivery systems like articulated arms suffer from beam rotation, pointing accuracy issues, optical losses, length limitations, and flexibility constraints, making it difficult to treat large or complex work pieces effectively.
Innovation Solution
A laser peening system that fixes the work piece and moves the laser beam using a relay imaging system with adjustable mirrors and a robot-mounted optical assembly, allowing for precise control and flexible beam delivery through a variable optical path, enabling the treatment of large work pieces without the need for extensive work piece movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the work piece is moved through the laser beam using automation, then the laser beam position can be held fixed, but the device complexity and cost increase due to holding fixtures and automation systems
Solution Approach 1:
Instead of moving the work piece through a fixed laser beam, the patent inverts the approach by fixing the work piece and moving the laser beam delivery system. This is achieved through a robotic arm that positions the laser source, eliminating the need for complex work piece handling fixtures while maintaining consistent laser incidence angles and spot sizes on the work piece surface.
Solution Approach 2:
The patent replaces the mechanical work piece movement system with an optical-mechanical hybrid system. A robotic arm with integrated laser source and optical components (mirrors, lenses) substitutes the conventional automation table and fixtures, providing both positioning and beam delivery functions in a single integrated system.
2Ease of operation
If conventional articulated arm beam delivery systems are used, then the laser beam can be delivered to the work piece, but beam rotation and pointing accuracy issues occur
Solution Approach 1:
The patent employs dynamic optical compensation where mirrors and lenses on the robotic arm are actively adjusted in real-time to compensate for beam rotation and pointing errors. The optical components are positioned and oriented dynamically as the robotic arm moves, maintaining precise beam delivery accuracy throughout the work piece surface.
Solution Approach 2:
The patent uses optical imaging systems that create a consistent virtual image of the laser source at a fixed position relative to the work piece. This optical copying mechanism ensures that the beam maintains consistent characteristics (spot size, orientation, incidence angle) regardless of the physical position of the robotic arm, effectively compensating for pointing errors.
3Area of stationary object
If the work piece size exceeds automation handling capacity, then larger structures can be treated, but conventional methods cannot be used
Solution Approach 1:
The patent transitions from two-dimensional work piece movement on a table to three-dimensional robotic arm positioning in space. The robotic arm can access large work pieces from multiple angles and positions, treating structures that extend beyond the confines of conventional automation tables, thereby enabling treatment of much larger area work pieces.
Solution Approach 2:
The integrated robotic arm with mounted laser source and optical components serves multiple functions: positioning the laser, delivering the beam, and maintaining beam characteristics. This universal system can treat work pieces of various sizes and shapes without requiring different equipment or fixtures, providing adaptability across different work piece dimensions.
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 reduces the complexity and cost of holding fixtures, allows for the effective laser peening of work pieces larger than typical automation handling capacities, and provides sufficient flexibility to treat large structures 'in situ' at customer facilities, maintaining the laser beam's spatial profile and orientation across the work piece surface.
Implementation Method 1
The laser beam follows an optical path that includes an essentially straight segment from the transmitting mirror to the receiving mirror
Implementation Method 2
The relay imaging system includes a transmitting mirror having an adjustable angle of incidence and a receiving mirror with an adjustable angle of incidence
Data Source
AI summary
A laser energy delivery system includes a relay imaging system. Input optics arranged to receive the laser energy, a transmitting mirror having adjustable angle of incidence relative to the input optics, and a robot mounted optical assembly are configured to direct laser energy toward the movable target image plane. The laser energy follows an optical path including an essentially straight segment from the transmitting mirror to the receiving mirror, having a variable length and a variable angle relative to the input optics through air. Diagnostics on the processing head facilitate operation.