Abstract:
This document discusses, among other things, methods and apparatus for a portable beam delivery system. In an example, an apparatus can include an enclosure including wheels, the enclosure configured to be moved about using the wheels, a laser system having a movable portion mounted to an outside surface of the enclosure, the moveable portion configured to provide a laser beam to a location determined by a position of the moveable portion and a position of the enclosure, and a controller enclosed within the enclosure, the controller configured to modulate an energy level of the laser beam.

Description:
TECHNICAL FIELD 
       [0001]    This application relates generally to automated web processing systems, and more particularly, to methods and apparatus for a portable beam delivery for automated web processing systems. 
       BACKGROUND 
       [0002]    There are various automated systems and methods for producing product. By way of example, automated web converting systems may process material from different rolls of material to form product. The continuous rolls of material are fed as “webs” through web processing components to form a new product that may be an intermediate or final product. Converting processes may include coating, laminating, printing, die cutting, slitting, and the like. Some converting equipment can offer flexible configurations that can easily change the sequence of converting operations such as die cutting and slitting. However, some converting operations, such as converting operations that make use of a laser, are very inflexible once such operation are installed on a converting machine. 
       SUMMARY 
       [0003]    This document discusses, among other things, methods and apparatus for a portable beam delivery system. In an example, an apparatus can include an enclosure including wheels, the enclosure configured to be moved about using the wheels, a laser system having a movable portion mounted to an outside surface of the enclosure, the moveable portion configured to provide a laser beam to a location determined by a position of the moveable portion and a position of the enclosure, and a controller enclosed within the enclosure, the controller configured to modulate an energy level of the laser beam. 
         [0004]    This Summary is an overview of some of the teachings of the present application and not intended to be an exclusive or exhaustive treatment of the present subject matter. Further details about the present subject matter are found in the detailed description and appended claims. Other aspects will be apparent to persons skilled in the art upon reading and understanding the following detailed description and viewing the drawings that form a part thereof, each of which are not to be taken in a limiting sense. The scope of the present invention is defined by the appended claims and their equivalents. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0005]      FIGS. 1A-1D  illustrate generally examples of portable beam delivery systems. 
           [0006]      FIG. 2  illustrates generally an example exhaust system for an example portable beam delivery system. 
           [0007]      FIG. 3  illustrates generally an example portable beam delivery system in position for delivering beam operations with web running on an adjacent converting machine. 
           [0008]      FIG. 4  illustrates generally a flowchart of an example method of using a portable beam delivery system. 
       
    
    
     DETAILED DESCRIPTION 
       [0009]    The present inventor has recognized a portable packaged system for delivering a beam, such as a laser beam, for production purposes. The system is capable of operating in multiple processing modes, thus allowing a user to adapt the beam delivery system to more than one product and, in certain examples, because the system is portable, to more than one production line or production area. In certain examples, even when the system has been positioned, the beam can be delivered to more than one location. 
         [0010]      FIG. 1  illustrates generally an example portable beam delivery system  100 . In certain examples, the portable beam delivery system  100  can include a portable support structure  101  and a moveable portion  103  coupled to the portable support system  101 . In certain examples, the portable support structure  101  can include wheels  104  for moving the beam delivery system  100  about a plant floor. In some examples, the wheels  104  can be locked in position to prevent the portable beam delivery system  100  from rolling. In some examples, the wheels  104  can be retracted to prevent the portable beam delivery system  100  from rolling. 
         [0011]    In certain examples, the portable support structure  101  can include a main enclosure  102  for housing support equipment such as a chiller  107 , an exhaust system (not shown), or combination thereof. In some examples, the portable support structure  101  can include an electrical enclosure  105  for housing control and electrical distribution components. In some examples, the portable support structure  101  can include an open frame instead of a main enclosure  102  to support the moveable portion  103  and to contain other components of the portable beam delivery system  100 , such as those components discussed below with regards to the main enclosure  102 . In certain examples, the open frame can include doors or panels to enclose some of the accessory components of the portable beam delivery system. In some examples, the moveable portion of the portable beam delivery system can be mounted to surfaces of an open frame support structure, such as external surfaces of an open frame support structure. In certain examples, the portable support structure  101  can include an enclosure to support the moveable portion  103  and the enclosure does not include a frame for supporting the moveable portion  103 . 
         [0012]    In certain examples, the main enclosure  102  can include an operator interface area  106  for mounting a display  108 , such as a touch screen. In some examples, the operator interface area  106  can include buttons, dials, and or switches for controlling or monitoring the beam delivery system In some examples, the main enclosure  102  can include a keyboard tray  109  for holding a keyboard that can be used to provide input information for controlling or monitoring the portable beam delivery system  100 . 
         [0013]    In certain examples, the moveable portion  103  of the beam delivery system can be mounted to an outside surface of the main enclosure  102 , such as the top of the main enclosure  102 . In some examples, the moveable portion  103  can be mounted to a side of the main enclosure  102 . In certain examples, the moveable portion  103  of the beam delivery system can include beam delivery hood  110 , a motion system  111  for positioning the beam delivery hood  110 , a beam generator  112 , such as a laser, and beam delivery optics  113  for providing an optical path from the beam generator  112  to the beam delivery hood  110 . 
         [0014]    In certain examples, the motion system  111  can include a rotary motion system to position the beam delivery hood  110 .  FIG. 1C  illustrates generally an example portable beam delivery system having a rotary motion system to position the beam delivery hood  110 . As shown in  FIG. 1A , in certain examples, the motion system  111  can include a cantilevered, linear motion system for extending and retracting the beam delivery hood  110  away from and toward the main enclosure  102 .  FIG. 1B  illustrates generally an example portable beam delivery system with the motion system  111  in an example retracted position. In some examples, the extended position of the linear motion system  111  can create a walkway, pathway or operator area  114  between the main enclosure  102  and the beam delivery hood  110 . In certain examples, the extended position can be set up as an “online” position of the portable beam delivery system  100  and the retracted position can be setup as an “offline” position of the portable beam delivery system  100 . In the “online” position, the portable beam delivery system  100  can integrate with and can perform production operations in coordination with a larger production line such as a converting line, a web line or a printing line, for example. In the “offline” position, the portable beam delivery system  100  can be used for test runs and experimentation. In certain examples, the retracted position can be set up as a second “online” position and can be used to integrate and perform production operations with a second production line. In certain examples, the extended position can be used as an “offline” position. In some examples, the retracted position provides an optimal position for efficiently preparing and safely shipping the portable beam delivery system  100  with minimal disassembly preparation. 
         [0015]    In certain examples, the moveable portion  103  can be moved and set in position manually. In such examples, a clamp or manual brake can be engaged to hold the moveable portion  103  at a desired position. In certain examples, the moveable portion  103  can include an actuator to move and position the moveable portion  103 . Such actuators can include, but are not limited to, a servo actuator, a pneumatic actuator or cylinder, a hydraulic actuator, a motor driven actuator, or a combination thereof. 
         [0016]    In certain examples, the moveable portion  103  can include a laser  112 , or laser system, for generating the beam. In certain examples, the laser system  112  can be sized and shaped to accommodate a variety of laser types and power ratings. In some examples, the portable beam delivery system  100  can be sized for 300-2000 W, 9.4 μm or 10.6 μm wavelength lasers. However, it is understood that other laser types and power rated lasers are possible for use with the portable beam delivery system  100  without departing from the scope of the present subject matter. In general, having the laser  112  as close to the processing area where the beam interfaces with the production materials can provide the best processing performance and efficiency. However, the laser  112  can be quite bulky and having the laser located close to the beam/production material interface  115  can eliminate options for using the laser  112  for other production purposes. In contrast, having the laser  112  located on the moveable portion  103  can provide a relatively short optical path from the laser  112  to the beam/production material interface  115  while at the same time allowing the location of the beam delivery to be moved about relatively easily, quickly, and efficiently. 
         [0017]    The beam delivery hood  110  can protect the beam path from interference at and near the beam/production material interface. In certain examples, the beam delivery hood  110  can include one or more transparent panels  116  to allow an operator to observe and monitor the operation of the portable beam delivery system  100  at and near the beam/production material interface. In certain examples, the beam delivery hood  110  can include hood duct  117  to allow fumes and waste material to be removed from the beam/production material interface area. In certain examples, the beam delivery hood  110  can enclose and protect at least a portion of the beam delivery optics  113 . In some examples, the beam delivery optics  113  can include a dynamic focusing module (DFM) to adjust the field of view of the portable beam delivery system  100 . In certain examples, the DFM can allow the spot size of the beam to be adjusted. In some examples, the DFM can allow a cutting depth of the beam to be adjusted. 
         [0018]    In certain examples, one or more idler rolls  130  can be integrated with the beam delivery hood. The idler rolls  130  can assist in moving production materials along a web path that interfaces with the delivered beam within the beam delivery hood  110 . In certain examples, auxiliary duct  115  can be integrated with the beam delivery hood  110  to provide a source of vacuum underneath the production materials relative to the beam delivery optics  113 . 
         [0019]    In certain examples, the main enclosure  102  can house a chiller  107  for providing cooling to the beam generator  112 . In certain examples, such as for a linear motion system, a flexible wire way  118  can provide protection and guidance for chiller cooling hoses and control wiring coupling the chiller  107  with the beam generator  112  housed in the moveable portion  103 . In certain examples, the chiller  107  can be positioned in the main enclosure  102  such that a display  119  of the chiller  107  can be monitored from a position external to the main enclosure  102 . In certain examples, the main enclosure  102  can house a portion of an exhaust system  120 . In certain examples, the exhaust system  120  can be used to remove fumes, smoke or gases produced as a result of interaction between the delivered beam and the production materials. 
         [0020]      FIG. 1B  also illustrates generally an example portable beam delivery system  100  with one or more doors of the main enclosure  102  removed to expose a chiller  107  and portions  121 ,  122  of an exhaust system  120 . 
         [0021]      FIG. 2  illustrates generally an example exhaust system  220  for an example portable beam delivery system, such as the example portable beam delivery systems  100  of  FIGS. 1A-1C . In certain examples, the exhaust system  220  can be used to remove waste production materials generated at or near the beam processing area. In certain examples, the exhaust system  220  can be used to remove waste production materials delivered to the beam processing area such as by production materials being conveyed via a web line, a converting line, or a printing line, for example. In some examples, the exhaust system  220  can be used to remove fumes, or fumes and waste production material. In certain examples, the exhaust system  220  can include a vacuum pump  221 , such as a vacuum pump powered by a motor, a waste collection device  222 , and duct  223 ,  224 ,  225  to provide vacuum to desired areas and to convey waste materials to the waste collection device  222 . In certain examples, the vacuum pump  221  can provide vacuum to the waste collection device  222  through first duct  223  and a filter  226  and can exhaust pumped air or gases through an exhaust vent  227 . As the air and gases move from machine duct  224 ,  225  through the waste collection device  222 , the filter  226  can capture waste product in the waste collection device  222 . 
         [0022]    In certain examples, at least a portion of the machine duct  224  can be coupled to hood duct  217  to provide vacuum at the beam delivery hood. In some examples, at least a portion of the machine duct can include auxiliary duct  225  to provide vacuum at other locations near the location of the portable beam delivery system. In some applications, production materials at and near the beam/production material interface are supported by idler rolls, a plate, or a table. In certain examples, auxiliary duct  225  can provide vacuum to a location underneath the production materials. In some applications, the beam delivery hood can include idler rolls for conveying a web of production material through the beam delivery hood and auxiliary duct  225  can be integrated with the beam delivery hood to direct fumes and waste material below the web. In certain applications, providing vacuum beneath the production materials can assist in operating the beam more efficiently as such vacuum can direct fumes and smoke away from the optical path of the beam and thus ameliorate such smoke and fumes from interfering with or attenuating the beam path. 
         [0023]    In certain applications, a portable beam delivery system including an exhaust system can provide multiple benefits to a plant operator. Such benefits can include, but are not limited to, eliminating the cost of a permanent exhaust system, eliminating the cost associated with providing exhaust to beam processing areas not currently serviced with an exhaust system, and eliminating safety concerns associated with temporarily providing exhaust to temporary beam processing areas. 
         [0024]      FIG. 1D  illustrates generally an alternative view of an example portable beam delivery system. In certain examples, the main enclosure  102  can includes louvers  131 , such as louvers  131  located on doors of the main enclosure  102 , to assure that the interior air pressure of the main enclosures is approximate equal to the external air pressure of the main enclosure. Substantial pressure differences between the internal and external air pressure of the main enclosure can cause unexpected motion of the enclosure doors when the door latches are released. 
         [0025]    Referring again to  FIG. 1A , in certain examples, a control system for a portable beam delivery system  100  can include a speed input, a position input, or a combination of a speed and position input such as an encoder or resolver input. In some examples, the speed or position input can be coupled to a speed or position sensor, such as an encoder  132  or a resolver, to provide speed or position information of process material to the controller of the portable beam delivery system  100 . In some examples, the speed or position information can be used to enable or disable the beam. In some examples, the speed or position information can be used to modulate one or more parameters of the beam generator  112  such as beam intensity, beam power, or beam energy, for example. In some examples, the speed or position information can be used to control a parameter of the chiller  107 . In some examples, the speed or position information can be used to control a parameter of the vacuum system  120  such as pump speed or a position of a vacuum control valve. In certain examples, an encoder  132  can be mounted to an idler roll, such as an idler roll  130  integrated with the beam delivery hood  110  to provide speed information of a web material  140  passing over the idler roll  130 . In certain examples, encoder wiring can use the flexible wireway  118  to couple the encoder  132  to the controller, such as a controller housed in the electrical enclosure  105 . 
         [0026]    Referring again to  FIG. 1A , in certain examples, a control system for a portable beam delivery system  100  can include a registration input. In some examples, registration input can be coupled to a registration sensor  133  to provide registration information of process or web material  140  to the controller of the portable beam delivery system  100 . In some examples, the registration information can be used to enable and disable the beam such that beam operations are registered to other landmarks of the process, production or web material  140 . 
         [0027]      FIG. 3  illustrates generally an example portable beam delivery system  300  in position for delivering beam operations with web running on an adjacent converting machine  350 . The converting machine  350  includes a configurable base module  351  with one or more modular stands  352  removed to expose how the web  340  can interface with the portable beam delivery system  300 . In certain examples, the portable beam delivery system  300  can include a main enclosure  302 , an electrical enclosure  305 , a moveable portion  303 , and a beam delivery hood  310  with integrated idler rolls as described above with reference to the examples of  FIGS. 1A-1D . The portable beam delivery system  300  is shown in  FIG. 3  with the a linear moveable portion  303  extended to provide beam processing at the converting machine  350 . If desired, the moveable portion  303  can be retracted to bring the beam delivery hood  310  closer to the main enclosure  302  to provide beam processing for a different application. If desired, the portable beam delivery system  300  can be moved, using wheels  304  attached to the main enclosure  302 , to a different location to provide beam processing for one or more other operations. 
         [0028]      FIG. 4  illustrates generally a flowchart of an example method  400  of using a portable beam delivery system. In certain examples, at  401 , the method can include using wheels mounted to an enclosure of the portable beam delivery system to move the portable beam delivery system to a processing area such as a web processing area or a workbench area. At  402 , a moveable portion of the portable beam delivery system can be used to present a laser beam to a location within the processing area. At  403 , the laser beam can be modulated to process materials using a controller housed in the enclosure. In certain examples, a vacuum system can evacuate fumes and waste material from the processing area as the laser beam is operating. In some examples, a cooling system can be used to cool the laser providing the laser beam. In some examples, the moveable portion can be moved to provide the beam at a second position such as a second web processing area or a second work bench area. The certain examples, modulating the beam can include using speed information received from an encoder mounted to a web processing line associated with the processing area. As discussed above, in some examples, the speed sensor can be mounted to a idler associated with a beam delivery hood of the portable beam delivery system. In some examples, modulating the beam can include using registration information received from a registration sensor associated with the material being processed by the laser beam. 
         [0029]    The methods illustrated in this disclosure are not intended to be exclusive of other methods within the scope of the present subject matter. Those of ordinary skill in the art will understand, upon reading and comprehending this disclosure, other methods within the scope of the present subject matter. The above-identified embodiments, and portions of the illustrated embodiments, are not necessarily mutually exclusive. These embodiments, or portions thereof, can be combined. In various embodiments, the methods are implemented using a sequence of instructions which, when executed by one or more processors, cause the processor(s) to perform the respective method. In various embodiments, the methods are implemented as a set of instructions contained on a computer-accessible medium such as a magnetic medium, an electronic medium, or an optical medium. 
         [0030]    The above detailed description is intended to be illustrative, and not restrictive. Other embodiments will be apparent to those of skill in the art upon reading and understanding the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.