XL SCAN

unbeatable precision meets large-field laser processing
XL SCAN is a combined scan solution jointly-developed by SCANLABand ACS Motion Control. This innovative solution enables maximum-precision processing of workpieces without size limitations.

Key Features• Scan solution for large-field processing

XL SCAN is based on the syncAXIS control Software’s novel
control concept unites synchronous scan head and XY stage
control with intelligent trajectory planning. XL SCAN thus delivers
the highest precision of all solutions currently on the market.
Maximum flexibility and enormous throughput increases areattainable by combining XL SCAN with several syncAXIS control
instances, multiple stages or multi-head systems.

• High throughput• Market-leading accuracy• No stitching errors

Typical Applications• High-dynamics processing without stage vibration• Large-field marking, cutting and engraving• Unlimited job duration• Processing of glass and foils• Automatic laser control, e.g. Spot Distance Control (SDC)• Micromachining• Capability of combining multiple software instances, stages
and scan heads• Drilling of large-area PCBsXL SCAN

Standard XL SCAN setup – schematic layoutHigh-End Laser Processing
The schematic diagram depicts XL SCAN’ssystem configuration. This scan solution
combines SCANLAB’s proven scan head
control with an XY stage positioned via
ACS’s innovative motion control system.

Windows PC
User program*.ct5

SCANLAB syncAXIS
control APIAPI
ACS SPiiPlus

SCANLAB
RTC6 PCIe

USB port

SCANLAB
DongleSL2-100

2nd scan head connector

SCANLAB scan head(excelliSCAN only)SL2-100
Ethernet

Typical System Components

ACS motion controller

SCANLAB

EtherCATACS SLEC converteretagySxStage

EtherCATACS motor drive

The laser spot’s movement across theworkpiece is automatically split between
the scan head and XY stage, thus assuring
optimal utilization of the entire system’s
available dynamics. The scan head isresponsible for short rapid motions, while
the stage extends the working surface.

Laserx Sc
anheaddhea
nacyS

XY positioning stage• sync AXIS control
software package for extended image
field processing.
• RTC6 PCIe (not Ethernet)
control board with SCANahead andsyncAXIS option• excelliSCAN 14
high-end scan headACSXL SCAN with 2 software instances, multiple stages and scan heads• ACS Controller
controls stage motion and EtherCATnetwork• ACS drives
adapted to system requirements• SLEC
interface between RTC6 PCIe control
board and ACS EtherCAT network
ACS components must be specified
in accordance with your system’s
requirements – contact ACS Motion
Control.
Components from external suppliers• XY stage• Laser
Additional Options• Multiple stages, syncAXIS control instances and scan heads

XL SCAN´s Processing Benefits

Unlimited Process Area
Until now, a scan head’s image field typically limited the working area’s size duringlaser processing. Conventional methods ofhandling very large workpieces are slow,
due to their section-wise (tiled) processing.

1

XL SCAN enables limitless extension ofworking fields, bounded only by the employed mechanical axes’ traversal range.
High Accuracy
excelliSCAN scan heads used in XL SCAN
produce no tracking error. The syncAXIS
control software´s trajectory planning calculates in advance the control of stage andscan head. The scan head has no need tocompensate positional deviations of thestage. Thus maximum system inaccuracyis defined solely by the sum of the scanhead’s and stage’s combined static positioning errors.
Moreover, an advanced servo control
algorithm prevents errors from workpiece
vibration caused by highly dynamic stage
motions.

Simultaneous movement enables 41% higher throughput(the number of additionally marked circles is indicated by thered marking)2

Stitching error(piecewise processing)

XL SCAN‘s simultaneous movement yields better processing
results

Increased Throughput
In many applications, controlling the scanhead and XY stage synchronously cansignificantly slash laser process times (seefigure 1): The throughput for small circularmarkings increased by 41%. Throughput
can additionally be multiplied by equipping
XL SCAN with several scan heads above astage.
No Stitching Errors
With XL SCAN, there’s no longer a need for
section-wise processing of large-area workpieces. Because the system enables full processing of the entire pattern, no stitchingerrors will occur (i.e. marking imprecisionnear image field borders, see figure 2).

3Large circle with detailed marking

Fast Circular Marking
Large detail-rich patterns can be createdwith maximum efficiency and accuracy.
For instance, XL SCAN makes marking afinely structured circular path both easy
and uncomplicated (see figure 3).

All user benefits are also shown in our XL SCAN video:
https://www.scanlab.de/en/products/advanced-scanning-solutions/xl-scansyncAXIS control Software

syncAXIS control Software
syncAXIS’s totally new control concept
eliminates the step conventional systems
often require of compensating positionaldeviations. The software’s integrated trajectory planning takes both the scan head’s
and the XY stage’s physical limitations intoaccount and controls them via intelligent
ﬁlters. That keeps the overall system nearlytracking-error-free, resulting in XL SCAN’s
high precision.
Many control systems on the market compensate stage motion positional deviations
by adjusting the scan head position. This
induces tracking errors that limit accuracy,particularly during fast jerky stage movements.
syncAXIS control software automatically splits motion paths of the scan head and stage

1

Pattern scanned without SDC function

Trajectory Planning supports
Smart Laser Control
2

Pattern scanned with SDC function

3without SDC

with SDC

Example of time saving with zig zag line
This example shows the combined stage`s and scan head`s motion path for marking a zig zag line.
On the left side, constant energy deposition is achieved via using sky writing. On the right side, spot
distance control (SDC) funtion is used for constant energy deposition, even in acceleration and deceleration phases. In this example production time is reduced by 38% with SDC.

The syncAXIS control software’s integrated trajectory planning enables straightforward control of modern USP lasers,
too. Users can define the laser spot’s pulse
spacing and energy densities, as well as
tolerable corner rounding. And users canconfigure detailed execution of process
patterns.
Look-ahead trajectory planning also fully
exploits the system’s maximum dynamics
capabilities – within user-specified tolerances. Complex-laser-path planning minimizes the laser-off times (e.g. during skywriting) and boosts effective throughput.

Automatic Laser Control with syncAXIS

Spot Distance Control (SDC)

1SCANLAB´s latest innovation is Spot Distance Control (SDC), an RTC6 PCIe control
board function included in the XL SCANpackage.
A signal to the laser control triggers alaser pulse or pulse train. For each clock
period, the SDC determines with a resolution of 64 MHz whether a pulse must beemitted to maintain the desired pulse spacing. With laser frequencies between 200
and 800 kHz, a maximum pulse distancedeviation of 2.5% is achievable.

SDC: Constant distance of center of laser pulses

2Contour-Dependent Laser Control
The SDC function maintains constant pulse
spacing regardless of the scan pattern. This
constant distance can be aligned either
along the centerline of the laser pulses
or tangential to the workpiece’s side. The
result is uniform workpiece edges (see figures 1 and 2). Even on sensitive materials,inhomogeneities and burn-ins are avoided.

SDC: Constant distance of laser pulse along workpiece side

Flexible Alteration of the Laser Signal
The laser signal can be raised or attenuated in accordance with application requirements. This applies to straight as wellas rounded laser markings. Even multiple
parameter changes and jumps for individual vectors are possible. Figure 3 shows
an example of flexibly changing the laserpower.
Deflection-Angle-Dependent Controlof Laser Signals
The laser’s spot size at the workpiece
depends on the laser beam’s deflection
angle through the scan head. syncAXIS
control’s ability to regulate laser parameters
based on the deflection angle enables thespot’s energy density to be held constant,even though the spot size varies minimallyalong the laser path (see figure 4). Thisfunction can be applied to any laser control
signal.

3

PL

Laser spot with high energy density
Laser spot with low energy density

Flexible alternation of laser power signal4αa)αb)Deflection angle-dependent energy densitya) without automatic laser controlb) with automatic laser control

α Deflection angle
High energy density
Low energy density

syncAXIS Control – Easy to use

syncAXIS Control´s Benefits• Highest precision and automatic laser
control by exact trajectory planning• Integrated Spot Distance Control (SDC)• Straightforward job planning• Logging mechanism for simplified
troubleshooting
Programming and Simulation
User applications for XL SCAN are based on
the syncAXIS control programming interface and can be developed using a dynamic link library (DLL). Its functions enable
the definition, loading and execution ofprocess jobs, as well as system parameter
configuration, status monitoring and usageof callback event functions.
GUI of syncAXIS Viewer

System initialization is achieved by simply
calling a function that loads a previously
defined configuration file.
Simulation Mode and Viewer
The program offers a simulation mode tolet you establish the ideal combination ofaccuracy and process speed, even without
connecting to hardware. The syncAXIS
Viewer facilitates evaluation of simulation
results and displays the scan head’s and XY
stage’s positional and dynamics values, aswell as the laser control signals.
syncAXIS Configurator
Parameters can be easily adjusted in thesyncAXIS Configurator. And programming is simplified thanks to automatic RTC
list handling. As soon as a configuration
file is correctly defined, users will no longer
need to account for list memory limitations.
The syncAXIS control Software’s logging
mechanism enables simple and efficienttroubleshooting.
Intuitive User Interface

Optional GUI for XL SCAN: SPiiPlusSPC

An optional graphical user interface (GUI)SPiiPlusSPC is available for controlling
XL SCAN. It lets you draw laser paths orimport them from CAD drawings. Asneeded, the software opens the syncAXIS
Configurator, where you can enter trajectory parameters or load simulation files atthe click of a button.

Large-Field Scanning Solutions

Stitch and Scan

2D Processing-on-the-ﬂy

XL SCAN

Stitch-and-scan is the conventional methodfor 2D-processing of large workpieces,whereby the scan head and XY stage moveseparately from another. The workpiecesurface is tiled into smaller sections of equal
size that can ﬁt within the scan head’s
image ﬁeld. Laser processing of all sections
occurs via the scan head while the stage
remains motionless. The XY stage only
moves to position the next section into thescan head’s image ﬁeld.

With Processing-on-the-ﬂy the scan head
and the XY stage move simultaneously.
The user programs the XY stage’s path inadvance. When processing with on-theﬂy mode, the RTC6 PCIe control board
subtracts stage motion from the overallmotion and then calculates the remaining
path for the scan head. A temporal offset
between the stage and scan head reduces
accuracy during the stage’s acceleration
and braking movements.

• Separate motions of the scan head and
XY stage• Simultaneous motion of scan head andXY stage• Low-budget solution possible with any
SCANLAB scan head

• Motion path for laser and XY stage has
to be programmed separately

XL SCAN‘s syncAXIS control software
automatically splits the laser’s motion
path into an XY stage path and a scanhead path. Both of these components are
perfectly synchronized and the laser islikewise triggered synchronously. The user
deﬁnes path-distribution parameters inaccordance with the application’s emphasis on accuracy or throughput. A simulation mode displays both the XY stage’s
and scan head’s individual positions anddynamics, thus facilitating optimal utilization of the scan head and stage. This solution is particularly beneﬁcial for OEMs,
who produce high volumes of the same
pattern.

• Supported by laserDESK (SCANLAB´sprofessional software for laser material
processing; incl. GUI)

• Synchronized motion of scan head andXY stage• Automatic splitting of laser path motion• Laser’s motion path has to be programmed in advance by the user
• Unique solution by SCANLAB and ACS
Motion Control

Overview of selected large field scanning solutions (with scan system and XY stage):
Solution

Flexibility

Throughput

AccuracyGUI

Applications

Stitch and Scan++

o+

Yes

Frequently-changing marking
applications

2D Processing on-the-ﬂy-++oYes

Similar patterns produced inlarge quantities

XL SCANo++++

Optional

Similar patterns produced inlarge quantities and with highaccuracy(++ excellent, + good;moderate, - poor)

Specifications

Specifications for excelliSCAN 14 with XL SCAN
Dynamics
Aperture [mm]TuningFocussing optic
Field of View
TuningTracking error [ms]Typical speeds (1)< 0.4
20 (5)< 0.5 mrad / 44°

Long-term drift (3), (4)8-h-drift (after 30 min warm-up)
Offset [µrad]< 20

Gain [ppm]< 20

Housing options

24-h-drift (after 3 h warm-up)< 30

Line scan / raster scan [m/s]< 30

Typical vector marking [m/s]<4Temperature drift (4)Good writing quality [cps]1000

Offset [µrad/K]< 10High writing quality [cps]850Gain [ppm/K]<4Offset [µrad]< 20

Gain [ppm]< 25(3)

0.28
0.88
3.70
51 000 (1),(2)Optical performance
Typical scan angle [rad]Gain error [mrad]
Zero offset [mrad]
Interface
Operating temperature [°C]
Weight [kg]at constant ambient temperature and load(4)
with water cooling(5)
based on the full angle range (e.g.
positioning resolution 0.7 µrad for angle range ± 0.36 rad)Wavelengths [nm]Power requirements±0.35<5<5SL2-100
25 ± 10approx. 7
Air- andwater cooling
355, 532, 1064
and others
30 V DC,max. 3 A(all angles are in optical degrees)with F-Theta objective, f = 160 mm
this corresponds to an angular acceleration of 3.2·105 rad/s2

ACS Motion Control is a global company providing EtherCAT network based high performance machine control systems for motion centric applications. Since 1985, ACS Motion
Control has provided state of the art control solutions to world leading manufacturers.
ACS Motion Control · 1 Ha-Ta‘asiya St. · Ramat Gabriel Industrial Park · P.O. Box 984
Migdal Ha-Emek 2307037 · ISRAEL
Tel. +(972) 4 6546-440 · Fax +(972) 4 6546-443
info@acsmotioncontrol.com · www.acsmotioncontrol.com

With over 35,000 systems produced annually, SCANLAB GmbH is the world-leading andindependent OEM manufacturer of scan solutions for deflecting and positioning laser beams
in three dimensions.
SCANLAB GmbH · Siemensstr. 2a · 82178 Puchheim · Germany
Tel. +49 (89) 800 746-0 · Fax +49 (89) 800 746-199
info@scanlab.de · www.scanlab.de
SCANLAB America, Inc. · 100 Illinois St · St. Charles, IL 60174 · USA
Tel. +1 (630) 797-2044 · Fax +1 (630) 797-2001
info@scanlab-america.com · www.scanlab-america.com

08/ 2021 Information is subject to change without notice.
Product photos are non-binding and may show customized features.

(2)

Repeatability (RMS) [µrad]
Positioning resolution [bit]Nonlinearity

Positioning, jump & shoot [m/s]Positioning times (1)1 mm jump width [ms]10 mm jump width [ms]100 mm jump width [ms]Acceleration [m/s2 ](1)

Further Specifications

Precision & Stability
14
universal
F-Theta objective
depending onobjective
universal0