Beam deflection optics SAO-m2 1.0x (3D)

Large area remote processing with high power solid state lasers

Schweißstrukturen
© Fraunhofer IWS Dresden
Schweißstrukturen

An investment in a fiber or disk laser requires the cost-effective utilization of this resource. For many application cases, a scanner system represents the most efficient variation of guiding the laser beam quickly and precisely and thus being able to do without costintensive CNC axes. Production costs per unit can be brought down by reducing cycle times, in addition it is desirable to minimize non-productive times. In this endeavor, aside from component handling, the infeed times of the machine tool play a large part. The current solution is only available for a very limited working area. On the other hand, an expansion by means of overlapping additional axis systems has a strong adverse effect on the economical advantages. Thus, there is a need for a beam deflection unit for highly dynamic solid state lasers with a large working area.

Our solution

Beam deflection optics SAO-m2 1.0x (3D)
© Fraunhofer IWS Dresden
Beam deflection optics SAO-m2 1.0x (3D)

With the development of the SAOm21.0x (3D) at the Fraunhofer IWS
Dresden, the solution proven for large area remote processing with CO2-lasers was successfully transferred to the field of solid state lasers. Working areas of 300 x 300 mm2 commonplace up to now have been enlarged 20-fold. A working distance of more than 2 m allows infeed rates in excess of 10 m s-1. The application of a gimbaled motion concept leads to significantly improved dynamic characteristics, while at the same time minimizing the number of optical elements.

An innovative mirror substrate and lightweight design in the area of moving components therefore allow an unequalled dynamism in the range of short wave lengths of 1 μm, thereby opening up new areas of application.

Functions

Laser-welded and subsequently hydro-formed heat exchanger plate
© Fraunhofer IWS Dresden
Laser-welded and subsequently hydro-formed heat exchanger plate

The newly developed processing optics are designed for stand-alone operation (i.e. without additional motion machinery). The working distance and the size of the working area are infinitely scalable by means of a mechanical adjusting device. The adaptive optics realize planfield correction and in addition enable processing of three-dimensional components.

The CAD/CAM interface with import function for common CAD formats allows intuitive programming by »drag and drop« directly on the virtual component. The control system provides an I/O module, which enables the actuation of the laser, valves and clamping devices directly from the scanner control. The flexibility allows short setup times and makes laser processing an interesting solution even for low volume serial production.

Areas of application

3D Patchworkstruktur als Verstärkungselement im Karosseriebau
© Fraunhofer IWS Dresden
3D Patchworkstruktur als Verstärkungselement im Karosseriebau

The SAO-m2 1.0x (3D) now makes versatile processing optics available for welding, heat treatment and lettering.

Areas of application are, for example, in body engineering in the automobile industry. Overlap welding of thin sheet metal, production of tailored blanks, welding-on of reinforcing elements or lettering of components are feasible. These production examples can be realized with the optics of the SAO-m2 1.0x (3D) without any additional motion machinery and offer an interesting alternative to conventional standard processing systems, even for smaller organizations.

Short setup times and quick programming allow the use of innovative laser technology in prototype construction, as well as in low volume serial production.

Specifications of SAO-m2 1.0x (3D)

Working distance 1 m to 3 m
Working area max. 2 x 2 m2
Laser output up to 4 kW
Wavelength 1030 nm to 1080 nm
Repeat accuracy +/- 175 μm at 2 m working distance
Jump speed up to 10 m s-1
Dimensions 650 mm x 450 mm x 300 mm
Weight approx. 35 kg