Laser marking using single-axis and multi-axis devices
Marking complex or high-value structures is one application of multi-axis positioning systems. For example, invisible marks, undetectable to the human eye, can be engraved onto objects using lasers. Workpiece movement in the X and Y axes, and laser objective positioning in the Z axis, are achieved using a high-dynamic direct-drive linear platform. The PI V-528 linear platform employs traditional stepper or rotary servo-based solutions to achieve the highest possible speed and scan frequency. The platform features crossed roller bearings, allowing for sub-micron accuracy with motors equipped with high repeatability and high-precision linear encoders.
For example, the PI V-417/V-817 series platforms are also well-suited for laser processing applications. These platforms offer positioning accuracy of only a few micrometers and speeds up to 2 meters per second. They can be easily combined for multi-axis applications.
The hard cap and side seals are specially designed to prevent dust or hot particles from entering the drive and encoder mechanical components. High-protection industrial connectors and locking pins provide enhanced robustness. The linear platform is easily aligned during installation due to a parallelism (//) of better than 50 micrometers between its specially shaped edges and the bearing guide or direction of movement.
The improved V-528 linear platform with gravity compensation is designed for vertical use.
XY configuration of the high-performance, robust V-417/V-817 linear platform
Wafer slicing using a planar scanner
The precision required for wafer separation dies is also crucial. The dicing width must remain constant, and perpendicular intersections are unavoidable. Furthermore, absolute precision is paramount to prevent damage to individual dies during the dicing process. The permissible tolerance within the stroke range is only a few micrometers per meter.
The PI A-322 air bearing platform, directly driven by a linear motor, is a positioning system ideally suited for such applications. This type of system can achieve high speeds, with accelerations up to 20 m/s². Simultaneously, sinusoidal commutation control enables smooth motion and positioning accuracy down to the nanometer level. The combination of control and mechanical components ensures maximum throughput and the highest precision.
A-322 Air Bearing Platform
Using a gantry system to manufacture templates and printed circuit boards
The manufacturing requirements for templates and printed circuit boards are similar. Workpiece size and feature density may be relatively high. The challenge lies in maintaining micron-level accuracy while providing long strokes. Gantry systems offer an excellent solution for these requirements. Cable management and operation are optimized to accommodate the vertical motion axis, autofocus sensors, and fiber optic routing systems for the laser. This design allows the part to remain stationary as the laser moves overhead. An absolute measurement system implemented by a PI sensor simplifies system initialization, eliminating the need for reference point finding after startup.
Laser using a multi-axis device including a galvanometer scanner
V-731 Series Positioning Platform
Marking
In laser forming, multi-axis positioning systems equipped with galvanometer scanners are typically used to deflect the laser beam. This enables excellent dynamics and precision, such as for marking graduations on functional components. In this case, the XY-axis motion is handled by the V-731 series positioning platform, which is configured as an XY-axis rolling platform. Its linear motor directly drives the platform without requiring additional mechanical components, making high speeds possible.
High-performance motion control system
In the laser processing flow described above, the laser can be conveniently controlled directly from the motion platform via a special laser module. This module enables direct control of the laser source, thereby improving the accuracy and throughput of the process.
ACS's LCM (Laser Control Module) series of EtherCAT® slave modules offers a variety of functions, including digital pulse modulation for dynamic power control, output pulses, or gating signals (switching signals), the latter two of which are synchronized with the position or programmable operating area along a two-dimensional to six-dimensional motion path. The control module can control virtually any laser through a universal interface.
EtherCAT® is an open fieldbus system based on Ethernet, originally developed by Beckhoff Automation. Today, as a robust, high-speed, real-time network for machine control solutions, EtherCAT is increasingly popular among control and systems engineers, largely due to the flexibility of fieldbus systems.
Large area marking without splicing
Typically, the operation of a motion system using a galvanometer scanner involves moving the part to be processed under the scanner and delegating control to the scanner controller to perform its individual operations. If the area to be processed is larger than the scanner's field of view, this method is performed in a manner known as "tillage." This method is ineffective for marking large areas with many small details. Small details may require higher acceleration, while large details require longer strokes. It may be more advantageous to use a fast and flexible galvanometer to separate small features of the trajectory, while a relatively slower, larger motion system platform handles large features. In this case, both systems need to have a synchronized controller architecture to supply the appropriate output to the correct motion platform.
Powered by ACS Motion Control and SCANLAB, the XLSCAN motion and gantry control system enables large-area marking and processing. Through synchronized control and movement of the 2D scanning head and a 2D scanning platform equipped with a highly dynamic magnetic linear drive, the XL scanning solution expands the working area of laser scanning systems. The combined system achieves large-area, effective marking with high throughput and accuracy.
