High precision – high throughput – synchronous 2D machining
Processing high-density structures over large areas, such as laser drilling or laser marking on PCBs, requires solutions that offer high precision and high throughput. The combination of a multi-axis positioning system and a high-dynamic galvanometer scanner can meet the demands of industrial production. The syncAXIS synchronous control PI XY displacement platform and the excelliSCAN galvanometer scanning system, the so-called XL SCAN method, allow for continuous operation over large areas, thus avoiding idle time and eliminating stitching errors. The ability to extend the field of view through the travel of each platform offers the advantage of fixing and maintaining optics in terms of accuracy, spot size, and performance.
Features of XL SCAN Automation Solution
Larger process area
Higher throughput
Higher machining precision down to the micrometer level
No stitching errors
Highly dynamic and stable machining without plateau vibration
Automatic laser control, such as spot distance control (SDC).
Multiple scanning heads and workpiece motion system functions
laser beam deflection
SCANLAB is a fast and accurate excelliSCAN scanning system with an XY- axis galvanometer scanner for beam control.
Workpiece positioning
For example, the V-551, used for linear motor platforms or planar scanners requiring high precision and speed, employs direct magnetic drive.
Drag chain cable management
Granite supports high precision and stability
Alternative arrangement of gantry moving scanning head for stationary workpieces
Automation control
SCANLAB, in collaboration with ACS Motion Control, has developed a motion control solution using EtherCAT -based industrial network-integrated digital scanner technology.
Synchronization between the galvanometer and the platform motion controller was achieved in the following way.
The system control software integrates process-level motion control, scanners, and lasers.
System running
The video showcases an advanced solution that can process surfaces by expanding the field of view of a galvanometer scanner while maintaining resolution and spot size.
Other industries and applications that benefit from the XL SCAN solution
Schematic diagram of standard XL SCAN device
The XL SCAN method synchronously coordinates the control of the workpiece motion system, scanner, and laser modulation. The XL SCAN control software automatically divides the desired pattern trajectory into the scanner path, the XY displacement platform path, and the laser spot control. The scanner receives short-range, high-frequency motion signals. The long-stroke positioning platform acquires low frequencies and expands the work area. The two movements are executed synchronously.
Processing characteristics
Larger process area and higher throughput
Traditional methods for processing large fields of view employ a " step-and-scan " approach, which divides the processing area into separate sections. This segmented processing is slow and produces stitching errors at the boundaries. XL SCAN provides a long-stroke extended workspace via a PI motion system, allowing for rapid, continuous movement across the extended field of view without stitching errors.
Higher precision
The XL SCAN method utilizes the zero tracking error of the excelliSCAN scanning head. Combined with XL SCAN trajectory planning, advanced acceleration-limited motion control, and a PI motion system with corresponding dynamics, straightness, flatness, and accuracy, high process precision can be achieved. The process precision of the scanning head is directly proportional to the distance from the processing point to the center of the scanning field. XL SCAN enables the scanning head to work close to the center of the FOV , which is directly related to precision .
Synchronous control of beam distance and pulse energy
Pulse energy and spot distance can be controlled synchronously. Spot distance control (SDC) outputs a single pulse or multiple pulses to the laser. SDC allows for constant energy deposition per unit length. The laser pulse is triggered based on the travel distance and is independent of the travel speed and the pattern of the laser path. Curves and straight lines can be processed at their respective maximum speeds while maintaining accuracy and maximizing possible throughput.
Laser power ramp and deflection angle control
For certain processing operations, it may be necessary to define specific laser power along a particular path. XL SCAN allows users to define power levels specifically for different sections of the path. Furthermore, the laser spot size depends on the deflection angle of the scanning head. XL SCAN 's deflection angle laser control keeps the energy density constant and reduces spot size variations along the laser path.
