CN110355996B - 用于积层制造的激光装置及其操作方法 - Google Patents
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Abstract
本发明公开一种用于积层制造的激光装置及其操作方法,其中所述用于积层制造的激光装置包含一激光射出单元、一分光单元、一控制单元及一镜组单元,利用所述分光单元及所述镜组单元的设计,将单一束激光分成两道或以上的光束,可减少制程表面的粗度以及缩短制程时间。
Description
技术领域
本发明是有关于一种激光装置及其操作方法,特别是关于一种用于积层制造的激光装置及其操作方法。
背景技术
积层制造技术又称3D打印或快速成型。它是一种以数字模块数据为基础,运用粉末状金属或塑料等可粘合材料或者熔丝,通过逐层堆叠累积的方式来构造物体的技术。目前常用的积层制造方法包含激光粉床熔融、电子束粉床熔融、激光同轴送粉及电弧熔丝成型。
其中的激光粉床熔融成形技术作为一种新型积层制造技术,不需要传统的模具、刀具、夹具及多道加工工序,在一台设备上可快速而精密地制造出任意复杂形状的零件,从而实现自由制造,解决许多过去难以制造的复杂结构零件,并大幅减少了加工工序,缩短了加工周期,而且愈是复杂结构产品,其优势愈为凸显。
然而,当前激光粉床熔融的制程所需的制程时间长,利用激光粉床熔融成型的平面表面较为粗糙(波浪状),而且所形成的组件容易因热应力而产生热变形。
因此,有必要提供一种改良的用于积层制造的激光装置及其操作方法,以解决现有技术所存在的问题。
发明内容
有鉴于此,本发明的主要目的在于提供一种用于积层制造的激光装置及其操作方法,利用分光单元及镜组单元的设计,将单一束激光分成两道或以上的光束,可减少制程表面的粗度及缩短制程时间。
为达上述的目的,本发明提供一种用于积层制造的激光装置,包含一激光射出单元、一分光单元、一控制单元及一镜组单元;所述激光射出单元配置用以发射一激光;所述分光单元配置用以接收所述激光,并将所述激光分光成多道光束;所述控制单元电性连接所述分光单元;所述镜组单元配置用以接收所述多道光束,并将所述多道光束朝一工作平台反射。
在本发明的一实施例中,所述分光单元具有一光斑调变镜组,所述光斑调变镜组设置在所述激光射出单元的一下游侧,配置用以接收所述激光,并调整所述激光的一光斑的尺寸。
在本发明的一实施例中,所述分光单元还具有一激光分光镜,所述激光分光镜设置在所述光斑调变镜组的一下游侧,配置用以接收从所述光斑调变镜组射出的激光,并将所述激光分光成所述多道光束。
在本发明的一实施例中,所述分光单元还具有一旋转单元,所述激光分光镜设置在所述旋转单元中,所述旋转单元配置用以使所述激光分光镜沿着从所述光斑调变镜组射出的激光的一光轴方向位移或旋转。
在本发明的一实施例中,所述分光单元还具有一间距调控镜组,所述间距调控镜组设置在所述激光分光镜的一下游侧,配置用以接收从所述激光分光镜射出的所述多道光束,并调整所述多道光束的一发散程度。
在本发明的一实施例中,所述镜组单元具有一扫描振镜组,所述扫描振镜组设置在所述间距调控镜组的一下游侧,配置用以接收从所述间距调控镜组射出的所述多道光束,使所述多道光束反射后沿一方向射往所述工作平台。
在本发明的一实施例中,所述镜组单元还具有一聚焦镜组,所述聚焦镜组设置在所述扫描振镜组的一出光侧,配置用以将所述多道光束聚焦至同一平面。
在本发明的一实施例中,所述激光装置是设置在一粉床熔融成型装置的一光路系统中。
为达上述的目的,本发明提供一种用于积层制造的激光装置的操作方法,包含一备置步骤、一分光步骤及一反射步骤,在所述备置步骤中,利用一激光射出单元产生一激光;在所述分光步骤中,利用一分光单元将所述激光分光成多道光束;在所述反射步骤中,利用一镜组单元将所述多道光束反射一工作平台。
在本发明的一实施例中,在所述分光步骤中,驱动所述分光单元的一激光分光镜沿着所述激光的一光轴方向位移或旋转。
如上所述,本发明用于积层制造的激光装置利用所述分光单元及所述镜组单元的设计,将单一束激光分成两道或以上的光束后,再聚焦照射在所述工作平台上,其中依据制程、扫描策略的需求控制所述多道光束的光斑(聚焦点)的间距与排列方向,以达成单振镜可调控多光束的激光制程,可减少制程表面粗度及缩短制程时间,而能够达到优化制程速度与精度的目的。
附图说明
图1是根据本发明用于积层制造的激光装置的一较佳实施例的一示意图。
图2是根据本发明用于积层制造的激光装置的一较佳实施例的旋转单元的一示意图。
图3a及3b是根据本发明用于积层制造的激光装置的一较佳实施例的多道光束发射至工作平台的一示意图。
图4a及4b是根据本发明用于积层制造的激光装置的一较佳实施例的多道光束发射至工作平台所实际呈现的态样的一示意图。
图5是根据本发明用于积层制造的激光装置的一较佳实施例的以单次激光扫描轨迹所实际呈现的态样的一示意图。
图6是根据本发明用于积层制造的激光装置的一较佳实施例的以二区激光扫描轨迹所实际呈现的态样的一示意图。
图7是根据本发明用于积层制造的激光装置的操作方法的一较佳实施例的一流程图。
实施方式
以下各实施例的说明是参考附加的图式,用以例示本发明可用以实施的特定实施例。再者,本发明所提到的方向用语,例如上、下、顶、底、前、后、左、右、内、外、侧面、周围、中央、水平、横向、垂直、纵向、轴向、径向、最上层或最下层等,仅是参考附加图式的方向。因此,使用的方向用语是用以说明及理解本发明,而非用以限制本发明。
请参照图1所示,为本发明用于积层制造的激光装置的一较佳实施例。其中所述激光装置是设置在一粉床熔融成型装置的一光路系统中(未绘示),而且所述激光装置包含一激光射出单元2、一分光单元3、一控制单元4及一镜组单元5。本发明将于下文详细说明各组件的细部构造、组装关系及其运作原理。
续参照图1所示,所述激光射出单元2配置用以发射一激光101,其中所述激光射出单元2具有一激光产生器21及一光准直器22(collimator),其中所述激光产生器21用以产生所述激光101往所述光准直器22射出,所述光准直器22配置用以协助将所述激光101的前进方向达到近乎平行直进程度的光(又称准直光或平行光)。
请参照图1及2所示,所述分光单元3配置用以接收所述激光101,并将所述激光101分光成多道光束102;所述分光单元3具有一光斑调变镜组31、一激光分光镜32、一旋转单元33及一间距调控镜组34。
进一步来说,所述光斑调变镜组31设置在所述激光射出单元2的一下游侧,配置用以接收所述激光101,并调整所述激光101的一光斑的尺寸;所述激光分光镜32设置在所述光斑调变镜组31的一下游侧,配置用以接收从所述光斑调变镜组31射出的激光101,并将所述激光101分光成所述多道光束102。在本实施例中,所述激光分光镜32可为一个多光束分光绕射光学组件(Diffraction Optical Element,DOE),所述激光101分光成多道光束102的数量为3道,但也可以依需求调整所述多道光束102的数量,例如:所述多道光束102的数量为3,5,7,9等奇数道的数量。
请参照图1及2所示,所述激光分光镜32设置在所述旋转单元33中,所述旋转单元33配置用以使所述激光分光镜32沿着从所述光斑调变镜组31射出的激光101的一光轴方向位移或旋转。在本实施例中,所述旋转单元33可为一回转式中空马达、或气浮/磁浮式轴承,其中图2所示的所述旋转单元33为气浮式轴承,具体来说,所述旋转单元33具有一外壳331、一定子332、多个空气入口333,所述定子332设置在所述外壳331中,所述空气入口333形成在所述外壳331上,所述激光分光镜32位于所述旋转单元33中而且为一转子。所述旋转单元33通过回转驱动与线性驱动马达(未绘示)以及链接至所述控制单元4(例如:计算机)的控制器进行驱动所述旋转单元33的回转转速及线性位置的定位控制,其中所述旋转单元33内部可安装所述激光分光镜32(如图2所示),而形成一可回转轴心设计的旋转机构,从而让所述激光分光镜32对于所述旋转单元33进行光束的回转。
续参照图1及2所示,所述间距调控镜组34设置在所述激光分光镜32的一下游侧,配置用以接收从所述激光分光镜32射出的所述多道光束102,并调整所述多道光束102的一发散程度。
续参照图1及2所示,所述控制单元4电性连接所述分光单元3的光斑调变镜组31、所述旋转单元33及所述间距调控镜组34,其中所述控制单元4可控制所述光斑调变镜组31来调整所述激光101的光斑的尺寸,在本实施例中,所述光斑调变镜组31是依光程的长短来改变光斑的聚焦位置,依据光轴方向进行光斑的大小调整。另外,所述控制单元4也可控制所述旋转单元33沿着所述激光101的光轴方向位移或以光轴为轴心进行旋转,例如:通过回转驱动及线性驱动马达及控制器进行驱动所述旋转单元33的回转转速及线性位置的定位控制,或者以所述光轴为轴心进行正转或反转,所述控制单元4还可控制所述间距调控镜组34来调整所述多道光束102的发散程度。
续参照图1及2所示,所述镜组单元5配置用以接收所述多道光束102,并将所述多道光束102朝一工作平台103反射,所述镜组单元5具有一扫描振镜组51及一聚焦镜组52,所述扫描振镜组51设置在所述间距调控镜组34的一下游侧,配置用以接收从所述间距调控镜组34射出的所述多道光束102,使所述多道光束102反射后沿一方向射往所述工作平台103;所述聚焦镜组52设置在所述扫描振镜组51的一出光侧,配置用以将所述多道光束102聚焦至同一平面。
参照图1并配合图3a及3b所示,所述激光分光镜32射出的所述多道光束102,经过所述间距调控镜组34、所述扫描振镜组51及所述聚焦镜组52而透射至所述工作平台103上,其中依第2道光束102的光斑的轴心为一回转轴X,通过驱动所述旋转单元33,所述第1道光束102的光斑及第3道光束102的光斑可依所述回转轴X为轴心进行回转及线性位置的定位控制,从而调控所述多道光束102之间距与排列方向,例如:图3a所示的较宽间距,第1道及第2道光束102之间距W1,及第2道及第3道光束102之间距W2,实际投射如图4a的态样;及图3b所示的较窄间距,第1道及第2道光束102之间距D1,及第2道及第3道光束102之间距D2,实际投射如图4b的态样。另外,如图5所示,为单次激光扫描轨迹(如实线所示)可同时扫描三条光束,与单一光束相比可节省约83%的激光扫描时间。又如图6所示,为二区(2-Zone)激光扫描轨迹(如实线及虚线所示),与单一光束相比可节省约66%的激光扫描时间,并获得较平坦的激光轨迹。
依据上述的结构,当所述激光101从所述光准直器22射出之后,即通过所述光斑调变镜组31调整所述激光101的光斑的尺寸,而后通过所述激光分光镜32将所述激光101分成所述多道光束,再通过所述间距调控镜组34调整因分光造成的所述多道光束间的发散程度;接着,通过所述控制单元4控制所述旋转单元33动作,使所述激光分光镜32沿着所述光轴方向进行位移,及以所述光轴为轴心进行旋转,从而调控所述多道光束102之间距与排列方向;最后通过所述扫描振镜组51将所述多道光束反射至所述工作平台103,同时,利用所述聚焦镜组52辅助将所述多道光束聚焦至同一平面来进行激光加工作业。
如上所述,本发明用于积层制造的激光装置利用所述分光单元3及所述镜组单元5的设计,将单一束激光分成两道或以上的光束后,再聚焦照射在所述工作平台103上,其中依据制程、扫描策略的需求控制所述多道光束的光斑(聚焦点)之间距与排列方向,以达成单振镜可调控多光束的激光制程,可减少制程表面粗度及缩短制程时间,而能够达到优化制程速度与精度的目的。
请参照图7并配合图1所示,本发明用于积层制造的激光装置的操作方法的一较佳实施例,是利用上述用于积层制造的激光装置进行操作,所述操作方法包含一备置步骤S201、一分光步骤S202及一反射步骤S203。本发明将于下文详细说明各步骤的运作流程。
续参照图7并配合图1所示,在所述备置步骤S201中,利用一激光射出单元2产生一激光101,在本实施例中,是利用一激光产生器21产生所述激光101往一光准直器22射出,再利用所述光准直器22协助将所述激光101的前进方向达到近乎平行直进程度的光。
续参照图7并配合图1所示,在所述分光步骤S202中,利用一分光单元3将所述激光101分光成多道光束102,接着驱动所述分光单元3的一激光分光镜32沿着所述激光101的一光轴方向进行位移,及以所述光轴为轴心进行旋转,从而调控所述多道光束102之间距与排列方向。
续参照图7并配合图1所示,在所述反射步骤S203中,利用一镜组单元5将所述多道光束反射一工作平台103,在本实施例中,是利用一扫描振镜组51将所述多道光束反射至所述工作平台103,同时,利用一聚焦镜组52辅助将所述多道光束聚焦至同一平面来进行激光加工作业。
如上所述,本发明用于积层制造的激光装置的操作方法,将单一束激光分成两道或以上的光束后,再聚焦照射在所述工作平台103上,其中依据制程、扫描策略的需求控制所述多道光束的光斑(聚焦点)之间距与排列方向,以达成单振镜可调控多光束的激光制程,可减少制程表面粗度及缩短制程时间,而能够达到优化制程速度与精度的目的。
本发明已由上述相关实施例加以描述,然而上述实施例仅为实施本发明的范例。必需指出的是,已公开的实施例并未限制本发明的范围。相反的,包含于权利要求书的精神及范围的修改及均等设置均包括于本发明的范围内。
Claims (7)
1.一种用于积层制造的激光装置,其特征在于:所述激光装置包含:
一激光射出单元,配置用以发射一激光;
一分光单元,配置用以接收所述激光,并将所述激光分光成多道光束,而且所述分光单元具有一光斑调变镜组、一激光分光镜及一旋转单元,所述光斑调变镜组设置在所述激光射出单元的一下游侧,配置用以接收所述激光,并调整所述激光的一光斑的尺寸,所述激光分光镜设置在所述光斑调变镜组的一下游侧,配置用以接收从所述光斑调变镜组射出的激光,并将所述激光分光成所述多道光束,所述激光分光镜设置在所述旋转单元中,所述旋转单元配置用以使所述激光分光镜沿着从所述光斑调变镜组射出的激光的一光轴方向位移或旋转,其中所述旋转单元具有一外壳、一定子、多个空气入口,所述定子设置在所述外壳中,所述空气入口形成在所述外壳上,所述激光分光镜位于所述旋转单元中而且为一转子;
一控制单元,电性连接所述分光单元;及
一镜组单元,配置用以接收所述多道光束,并将所述多道光束朝一工作平台反射。
2.如权利要求1所述的用于积层制造的激光装置,其特征在于:所述分光单元还具有一间距调控镜组,所述间距调控镜组设置在所述激光分光镜的一下游侧,配置用以接收从所述激光分光镜射出的所述多道光束,并调整所述多道光束的一发散程度。
3.如权利要求2所述的用于积层制造的激光装置,其特征在于:所述镜组单元具有一扫描振镜组,所述扫描振镜组设置在所述间距调控镜组的一下游侧,配置用以接收从所述间距调控镜组射出的所述多道光束,使所述多道光束反射后沿一方向射往所述工作平台。
4.如权利要求3所述的用于积层制造的激光装置,其特征在于:所述镜组单元还具有一聚焦镜组,所述聚焦镜组设置在所述扫描振镜组的一出光侧,配置用以将所述多道光束聚焦至同一平面。
5.如权利要求1所述的用于积层制造的激光装置,其特征在于:所述激光装置是设置在一粉床熔融成型装置的一光路系统中。
6.一种如权利要求1所述的用于积层制造的激光装置的操作方法,其特征在于:所述操作方法包含步骤:
一备置步骤,利用一激光射出单元产生一激光;
一分光步骤,利用一分光单元将所述激光分光成多道光束;及
一反射步骤,利用一镜组单元将所述多道光束反射一工作平台。
7.如权利要求6所述的用于积层制造的激光装置的操作方法,其特征在于:在所述分光步骤中,驱动所述分光单元的一激光分光镜沿着所述激光的一光轴方向位移或旋转。
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