Ultra-long steel strip grating manufacturing system and manufacturing method using femtosecond laser with spatiotemporal parameters cooperative control

Abstract

An ultra-long steel strip grating manufacturing system using femtosecond laser with spatiotemporal parameters cooperative control, the manufacturing system comprising an unwinding roller, a traction roller and a winding roller, a linear femtosecond laser unit and an electronic shutter being disposed between the unwinding roller and the traction roller and directly above the electronic shutter, a cleaning unit being disposed between the traction roller and the winding roller, a first inspection unit being disposed between the cleaning unit and the winding roller, a second inspection unit being disposed directly above the winding roller, and a plurality of auxiliary roller systems which are driven rollers being disposed along a conveying direction of the steel strip, which achieves a horizontal movement of the steel strip under the electronic shutter, and also achieves a smooth entry of the steel strip into the cleaning unit for cleaning.

Claims

1. An ultra-long steel strip grating manufacturing system using femtosecond laser with spatiotemporal parameters cooperative control, the manufacturing system comprising an unwinding roller (2), a traction roller (1) and a winding roller (6), a linear femtosecond laser unit (3) and an electronic shutter (4) being disposed between the unwinding roller (2) and the traction roller (1) and directly above the electronic shutter (4), a cleaning unit (5) being disposed between the traction roller (1) and the winding roller (6), a first inspection unit (7-1) being disposed between the cleaning unit (5) and the winding roller (6), a second inspection unit (7-2) being disposed directly above the winding roller (6), and a plurality of auxiliary roller systems (8-i) which are driven rollers being disposed along a conveying direction of the steel strip, which achieves a horizontal movement of the steel strip under the electronic shutter (4), and also achieves an entry of the steel strip into the cleaning unit (5) for cleaning; wherein the traction roller (1) is a driving roller rotating at a spatial angular velocity .sub.1, and the winding roller (6) is a driving roller with a spatial angular velocity .sub.2; and the outer cylindrical surface of the traction roller (1) has a magnetic or negative pressure structure, and the horizontal movement velocity is V=R.sub.1.sub.1 when the steel strip passes under the electronic shutter (4), wherein R.sub.1 is a radius of the traction roller (1); wherein the linear femtosecond laser unit (3) is composed of a femtosecond laser (3-1), a galvanometer (3-2), a focusing lens set (3-3), and its output is a linear femtosecond laser spot; and the temporal switching frequency of the electronic shutter (4) is f; wherein a length of the linear femtosecond laser spot is ranged from 2 to 10 mm, and a width of the spot is ranged from 0.5 to 200 m; and the steel strip is a stainless steel strip having flexibility with a thickness ranging from 0.1 to 1.5 mm, a width ranging from 3 to 15 mm and a length ranging from 1 to 500 m; and wherein the winding roller (6) is composed of a metal rigid member (6-1) and a plastic elastic member (6-2); the inner ring of the metal rigid member (6-1) is provided with rigid inner teeth; each of elastic arms of the plastic elastic member (6-2) is of hollow structure, and its end is provided with elastic outer teeth engaged with the rigid inner teeth; the metal rigid member (6-1) and the plastic elastic member (6-2) are fitted with each other to achieve overload protection; when (R.sub.2+r).sub.2>R.sub.1.sub.1, the winding roller (6) idles to ensure that the rotation of the winding roller (6) does not affect a stability of rotating speed of the traction roller (1), wherein R.sub.2 is a radius of the winding roller (6), .sub.2 is an angular velocity of the winding roller (6), and r is an increment of an equivalent radius of the winding roller (6) introduced by winding process of the steel strip grating.

2. The manufacturing system according to claim 1, wherein the first inspection unit (7-1) is an optical microscope; the second inspection unit (7-2) is a laser triangular displacement sensor; and a cleaning agent used in the cleaning unit (5) is absolute ethyl alcohol.

3. The manufacturing system according to claim 1, wherein the traction roller (1) is further connected with a large reduction-ratio reducer (9); the large reduction-ratio reducer (9) includes a precision driving gear (9-1) and a precision driven gear (9-2) to constitute a reduction transmission structure, and has a reduction ratio of K; the precision driving gear (9-1) driven by an electric motor has a spatial angular velocity of .sub.0; the traction roller (1) is a driven wheel with a spatial angular velocity of .sub.1=K.sub.0; the constant velocity of horizontal movement of the ultra-long steel strip grating is V=R.sub.1.sub.1=KR.sub.1.sub.0, wherein R.sub.1 is the radius of the traction roller (1).

4. A method for manufacturing ultra-long steel strip grating using the manufacturing system according to claim 1, comprising the following steps: S1. feeding the steel strip substrate: loading the steel strip in roll into the unwinding roller (2), and pulling a beginning end of the steel strip through the traction roller (1), the cleaning unit (5), the winding roller (6), and the auxiliary roller system (8-i), to complete pre-tensioning of the steel strip to be processed; S2. setting system parameters which comprises steps of: S2-1. setting the spatial angular velocity .sub.1 and f: geometric structure features of the steel strip grating scale being cooperatively controlled by the spatial angular velocity .sub.1 of the traction roller (1) and the temporal parameter f of the electronic shutter (4), and a grating period of the steel strip grating being P: $\begin{array}{cc}P=V/f=R_1{}_1/f& \left(1\right)\end{array}$ wherein, R.sub.1 is the radius of the traction roller (1); the radius R.sub.1 of the traction roller (1) being a known quantity, and the spatial angular velocity .sub.1 of the traction roller (1) and the temporal switching frequency f of the electronic shutter being set to meet the constraint condition P=R.sub.1.sub.1/f by taking a structural dimension P of the steel strip grating as a target value; S2-2. setting the spatial angular velocity .sub.2: the radius R.sub.2 of the winding roller (2) being a known quantity, and setting the spatial angular velocity .sub.2 to meet the constraint condition R.sub.2.sub.2=(0.7 to 0.8)R.sub.1.sub.1; S.sub.3. moving the steel strip at a constant velocity: the traction roller (1) driven by the electric motor rotating at the spatial angular velocity .sub.1, driving the steel strip to be continuously output at a constant velocity from the unwinding roller (2), passing through the auxiliary roller system (8-i), and moving horizontally under the electronic shutter (4); S4. processing the grating with the femtosecond laser: the linear femtosecond laser unit (3) performing localized processing on the steel strip moves horizontally at a constant velocity under the regulation of the temporal switching frequency f of the electronic shutter (4) to form the steel strip grating scale; S5. cleaning and inspecting the steel strip grating: the manufactured steel strip grating scale being cleaned by the cleaning unit (5), and the first inspection unit (7-1) conducting online quality inspection of the cleaned steel strip grating scale; S6. winding and storing the steel strip grating: under the action of the winding roller (6), the steel strip grating scale being gradually wound on the winding roller (6), and the second inspection unit (7-2) monitoring the equivalent radius increment r of the winding roller (6) in real time; when r reaches a threshold, the winding roller (6) achieving overload protection, then a staff cutting the steel strip grating and removing the outer ring of the current winding roller and the steel strip grating roll, and completing a roll-up storage of the current steel strip grating; replacing with next outer ring of the winding roller and continuing to wind and store the steel strip grating; and S7. continuously feeding and processing the steel strip: after the processing of the current steel strip substrate wound on the unwinding roller (2), replacing with a next roll of steel strip, repeating the steps of S1-S6, and starting the processing for grating of the next roll of steel strip.

5. A method for manufacturing ultra-long steel strip grating using the manufacturing system according to claim 3, comprising the following steps: S1. feeding the steel strip substrate: loading in roll the steel strip into the unwinding roller (2), and pulling a beginning end of the steel strip through the traction roller (1), the cleaning module (5), the winding roller (6), and the auxiliary roller system (8-i), to complete pre-tensioning of the steel strip to be processed; S2. setting system parameters which comprises steps of: S2-1. setting the spatial angular velocity .sub.1 and f: geometric structure features of the steel strip grating being cooperatively controlled by the spatial angular velocity .sub.0 of the precision gear (9-1) and the temporal parameter f of the electronic shutter (4), and a grating period of the steel strip grating being P: $\begin{array}{cc}P=V/f={\mathrm{KR}}_1{}_0/f& \left(2\right)\end{array}$ wherein R.sub.1 is the radius of the traction roller (1). the radius R.sub.1 of the traction roller (1) being a known quantity, and the spatial angular velocity wo of the precision gear (9-1) and the temporal switching frequency f of the electronic shutter being set to meet the constraint condition P=KR.sub.1.sub.0/f by taking a structural dimension P of the steel strip grating as a target value; S2-2. setting the spatial angular velocity .sub.2: the radius R.sub.2 of the winding roller (2) being a known quantity, and setting the spatial angular velocity @2 to meet the constraint condition R.sub.2.sub.2=(0.7 to 0.8)R.sub.1.sub.1; S3. moving the steel strip at a constant velocity: the traction roller (1) driven by the electric motor rotating at the spatial angular velocity 1, driving the steel strip to be continuously output at a constant velocity from the unwinding roller (2), passing through the auxiliary roller system (8-i), and moving horizontally under the electronic shutter (4); S4. processing the grating with the femtosecond laser: the linear femtosecond laser unit (3) performing localized processing on the steel strip moves horizontally at a constant velocity under the regulation of the temporal switching frequency f of the electronic shutter (4) to form the steel strip grating scale; S5. cleaning and inspecting the steel strip grating: the manufactured steel strip grating scale being cleaned by the cleaning unit (5), and the first inspection unit (7-1) conducting an online quality inspection of the cleaned steel strip grating scale; S6. winding and storing the steel strip grating: under the action of the winding roller (6), the steel strip grating scale being gradually wound on the winding roller (6), and the second inspection unit (7-2) monitoring the equivalent radius increment r of the winding roller (6) in real time; when r reaches a threshold, the winding roller (6) achieving overload protection, then a staff cutting the steel strip grating and removing the outer ring of the current winding roller and the steel strip grating roll, and completing a roll-up storage of the current steel strip grating; replacing with next outer ring of the winding roller and continuing to wind and store the steel strip grating; and S7. continuously feeding and processing the steel strip: after the processing of the current steel strip substrate wound on the unwinding roller (2), replacing with a next roll of steel strip, repeating the steps of S1-S6, and starting the processing for grating of the next roll of steel strip.

6. The method according to claim 4, wherein a dimension range of the steel strip grating period P ranges from 1 to 400 m, and an accuracy range of P ranges from 5 to 50 nm.

7. The method according to claim 5, wherein a dimension range of the steel strip grating period P ranges from 1 to 400 m, and an accuracy range of P ranges from 5 to 50 nm.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 is a schematic diagram of the system working principle of Embodiment 1 of the present disclosure.

(2) FIG. 2 is a schematic view of the system structure of Embodiment 1 of the present disclosure.

(3) FIG. 3 is a schematic view of the traction roller structure of Embodiment 1 of the present disclosure.

(4) FIG. 4 is a schematic view of a structure of the linear femtosecond laser module of Embodiment 1 of the present disclosure.

(5) FIG. 5 is a schematic view of an overload protection structure of the winding roller of Embodiment 1 of the present disclosure.

(6) FIG. 6 is a schematic view of the system structure of Embodiment 2 of the present disclosure.

DESCRIPTION OF EMBODIMENTS

(7) The In order to make the object, technical solutions and advantages of the present disclosure clearer, the present disclosure is further described in detail below in conjunction with the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are only intended to explain the present disclosure and do not constitute a limitation of the present disclosure. Based on the embodiments in the present disclosure, all other embodiments obtained by those of ordinary skill in the art without making creative labor, fall within the scope of the protection of the present disclosure.

Embodiment 1

(8) Refer to FIGS. 1-5, an ultra-long steel strip grating manufacturing system using femtosecond laser with spatiotemporal parameters cooperative control is shown. The manufacturing system includes an unwinding roller 2, a traction roller 1 and a winding roller 6. A steel strip is released from the unwinding roller 2, passes through the traction roller 1 in turn, and finally is wound on the winding roller 6. A linear femtosecond laser unit 3 and an electronic shutter 4 are disposed between the unwinding roller 2 and the traction roller 1 and directly above the electronic shutter 4. A cleaning unit 5 is disposed between the traction roller 1 and the winding roller 6. A first inspection unit 7-1 is disposed between the cleaning unit 5 and the winding roller 6, and a second inspection unit 7-2 is disposed directly above the winding roller 6. A plurality of auxiliary roller systems 8-i which are driven rollers are disposed along a conveying direction of the steel strip, achieving a horizontal movement of the steel strip under the electronic shutter 4, and also a smooth entry of the steel strip into the cleaning unit 5 for cleaning. Wherein the first inspection unit 7-1 is used for online inspection of the manufacturing quality of the grating and the second inspection unit 7-2 is used for the real-time monitoring of the outer diameter of the winding.

(9) The traction roller 1 is a driving roller rotating at a spatial angular velocity .sub.1 which drives the steel strip to output from the unwinding roller 2 at a constant velocity, and the winding roller 6 is a driving roller with a spatial angular velocity .sub.2 which is used for achieving the roll-up storage of the grating scale.

(10) Preferably, the outer cylindrical surface of the traction roller 1 has a magnetic or negative pressure structure, so that the steel strip fit stably with the transmission cylinder surface of the traction roller 1, preventing the risk of slippage between the steel strip substrate and the traction roller 1, and realizing the continuous horizontal movement at a constant velocity of the ultra-long steel strip substrate. The horizontal movement velocity is V=R.sub.1.sub.1 when the steel strip passes under the electronic shutter, wherein R.sub.1 is a radius of the traction roller 1.

(11) The linear femtosecond laser unit 3 is composed of a femtosecond laser 3-1, a galvanometer 3-2, and a focusing lens set 3-3. A punctate spot output by the femtosecond laser 3-1 is irradiated to the surface of the galvanometer 3-2. When the galvanometer 3-2 is stationary, the laser is reflected to form a punctate spot, and when the galvanometer 3-2 rotates at high speed, the reflective surface changes at high speed so that the punctate laser spot becomes a linear spot. The focusing lens set 3-3 focus the linear spot further to form a linear femtosecond laser spot with a very small width. Its output linear femtosecond laser spot.

(12) Preferably, a length of the linear femtosecond laser spot is ranged from 2 to 10 mm, and a width of the spot is ranged from 0.5 to 200 m.

(13) The temporal switching frequency of the electronic shutter 4 is f, and the frequency f can be programmed to control the linear femtosecond laser spot to selectively perform localized processing on the steel strip moves horizontally at a constant velocity to form the steel strip grating scale.

(14) Preferably, the cleaning agent used in the cleaning unit 5 is absolute ethyl alcohol.

(15) Preferably, the winding roller 6 is composed of a metal rigid member 6-1 and a plastic elastic member 6-2. The inner ring of the metal rigid member 6-1 is provided with rigid inner teeth. Each of elastic arms of the plastic elastic member 6-2 is hollow, and its end is provided with elastic outer teeth engaged with the rigid inner teeth. The metal rigid member 6-1 and the plastic elastic member 6-2 are fitted with each other to achieve overload protection. When (R.sub.2+r) .sub.2>R.sub.1.sub.1, the winding roller 6 overload and idle to ensure that the rotation of the winding roller 6 does not affect a stability of rotating speed of the traction roller 1, wherein R.sub.2 is a radius of the winding roller 6, .sub.2 is an angular velocity of the winding roller 6, and r is an increment of an equivalent radius of the winding roller 6 introduced by winding process of the steel strip grating.

(16) Preferably, the first inspection unit 7-1 is an optical microscope and the second inspection unit 7-2 is a laser triangular displacement sensor.

(17) The steel strip is a stainless steel strip having certain flexibility.

(18) Preferably, the steel strip has a thickness ranging from 0.1 to 1.5 mm, a width ranging from 3 to 15 mm and a length ranging from 1 to 500 m.

(19) A manufacturing process utilizing the ultra-long steel strip grating manufacturing system using femtosecond laser with spatiotemporal parameters cooperative control includes the following steps: S1. feeding the steel strip substrate: loading the steel strip in roll into the unwinding roller 2, and pulling a beginning end of the steel strip through the traction roller 1, the cleaning unit 5, the winding roller 6, and the auxiliary roller system 8-i, to complete pre-tensioning of the steel strip to be processed; S2. setting system parameters which includes sub-steps of S2-1 and S2-2: S2-1. setting the spatial angular velocity .sub.1 and f: geometric structure features of the steel strip grating scale being cooperatively controlled by the spatial angular velocity .sub.1 of the traction roller 1 and the temporal parameter f of the electronic shutter 4, and a grating period of the steel strip grating being P:

(20) $\begin{array}{cc}P=V/f=R_1{}_1/f& \left(1\right)\end{array}$ wherein, R.sub.1 is the radius of the traction roller 1; it can be seen from Equation (1) that the nominal value of P is determined by the parameter matching combination of the spatial angular velocity .sub.1 and the temporal parameter f, and the accuracy of P is determined by the control accuracy of the spatial angular velocity .sub.1 and the temporal parameter f; the radius R.sub.1 of the traction roller 1 being a known quantity, and the spatial angular velocity .sub.1 of the traction roller 1 and the temporal switching frequency f of the electronic shutter being set to meet the constraint condition P=R.sub.1.sub.1/f by taking a structural dimension P of the steel strip grating as a target value; S2-2. setting the spatial angular velocity .sub.2: the radius R.sub.2 of the winding roller 2 being a known quantity, and setting the spatial angular velocity .sub.2 to meet the constraint condition R.sub.2.sub.2=(0.70.8)R.sub.1.sub.1; S3. moving the steel strip at a constant velocity: the traction roller 1 driven by the electric motor rotating at the spatial angular velocity .sub.1, driving the steel strip to be continuously output at a constant velocity from the unwinding roller 2, pass through the auxiliary roller system 8-i, and move horizontally under the electronic shutter 4; S4. processing the grating with the femtosecond laser: the linear femtosecond laser unit 3 performing localized processing on the steel strip moves horizontally at a constant velocity under the regulation of the temporal switching frequency f of the electronic shutter 4 to form the steel strip grating scale; S5. cleaning and inspecting the steel strip grating: the manufactured steel strip grating scale being cleaned by the cleaning unit 5, and the first inspection unit 7-1 conducting an online quality inspection of the cleaned steel strip grating scale; S6. winding and storing the steel strip grating: under the action of the winding roller 6, the steel strip grating scale being gradually wound on the winding roller 6, and the second inspection unit 7-2 monitoring the equivalent radius increment r of the winding roller 6 in real time; when r reaches a threshold, the winding roller 6 achieving overload protection, then a staff cutting the steel strip grating and removing the outer ring of the current winding roller and the steel strip grating roll, and completing a roll-up storage of the current steel strip grating; replacing with next outer ring of the winding roller and continuing to wind and store the steel strip grating; and S7. continuously feeding and processing the steel strip: after the processing of the current steel strip substrate wound on the unwinding roller 2, replacing with a next roll of steel strip, repeating the steps of S1-S6, and starting the processing for grating of the next roll of steel strip.

(21) Preferably, a dimension range of P is 1-400 m, and an accuracy range of P is 5-50 nm.

Embodiment 2

(22) Refer to FIG. 6, compared with Embodiment 1, the traction roller 1 is connected with a large reduction-ratio reducer 9.

(23) The large reduction-ratio reducer 9 includes precision gears 9-1 and 9-2 to constitute a reduction transmission structure, and has a reduction ratio of K. The precision gear 9-1 is a driving gear and has a spatial angular velocity of .sub.0 under the driving of an electric motor.

(24) The traction roller 1 is a driven wheel with a spatial angular velocity of .sub.1=K.sub.0, thus the constant velocity of horizontal movement of the ultra-long steel strip grating is V=R.sub.1.sub.1=KR.sub.1.sub.0, wherein R.sub.1 is the radius of the traction roller 1.

(25) The geometric structure features of the steel strip grating are cooperatively controlled by the spatial angular velocity .sub.0 of the precision gear 9-1 and the temporal parameter f of the electronic shutter 4, and a grating period of the steel strip grating is:

(26) $\begin{array}{cc}P=V/f={\mathrm{KR}}_1{}_0/f& \left(2\right)\end{array}$

(27) In Equation (2), K and R.sub.1 are known quantities so that the nominal value of P is determined by the parameter matching combination of the spatial angular velocity .sub.0 and the temporal parameter f, and the accuracy of P is determined by the control accuracy of the spatial angular velocity .sub.0 and the temporal parameter f.

(28) A manufacturing process utilizing the ultra-long steel strip grating manufacturing system using femtosecond laser with spatiotemporal parameters cooperative control includes the following steps: S1. feeding the steel strip substrate: loading the steel strip in roll into the unwinding roller 2, and pulling a beginning end of the steel strip through the traction roller 1, the cleaning unit 5, the winding roller 6, and the auxiliary roller system 8-i, to complete pre-tensioning of the steel strip to be processed; S2. setting system parameters which includes sub-steps S2-1 and S2-2: S2-1. setting parameters .sub.0 and f: the radius R.sub.1 of the traction roller 1 being a known quantity, and the spatial angular velocity .sub.0 of the precision gear 9-1 and the temporal switching frequency f of the electronic shutter being set to meet the constraint condition P=KR.sub.1.sub.0/f by taking a structural dimension P of the steel strip grating as a target value; S2-2. setting parameter .sub.2: the radius R.sub.2 of the winding roller 2 being a known quantity, and setting the spatial angular velocity .sub.2 to meet the constraint condition R.sub.2.sub.2=(0.70.8)R.sub.1.sub.1; S3. moving the steel strip at a constant velocity: the traction roller 1 driven by the electric motor rotating at the spatial angular velocity .sub.1, driving the steel strip to be continuously output at a constant velocity from the unwinding roller 2, pass through the auxiliary roller system 8-i, and move horizontally under the electronic shutter 4; S4. processing the grating with the femtosecond laser: the linear femtosecond laser unit 3 performing localized processing on the steel strip moves horizontally at a constant velocity under the regulation of the temporal switching frequency f of the electronic shutter 4 to form the steel strip grating scale; S5. cleaning and inspecting the steel strip grating: the manufactured steel strip grating scale being cleaned by the cleaning unit 5, and the first inspection unit 7-1 conducting an online quality inspection of the cleaned steel strip grating scale; S6. winding and storing the steel strip grating: under the action of the winding roller 6, the steel strip grating scale being gradually wound on the winding roller 6, and the second inspection unit 7-2 monitoring the equivalent radius increment r of the winding roller 6 in real time; when r reaches a threshold, the winding roller 6 achieving overload protection, then a staff cutting the steel strip grating and removing the outer ring of the current winding roller and the steel strip grating roll, and completing a roll-up storage of the current steel strip grating; replacing with next outer ring of the winding roller and continuing to wind and store the steel strip grating; and S7. continuously feeding and processing the steel strip: after the processing of the current steel strip substrate wound on the unwinding roller 2, replacing with a next roll of steel strip, repeating the steps of S1-S6, and starting the processing for grating of the next roll of steel strip.

(29) Comparing Equations (1) and (2), it can be seen that according to Equation (1), assuming that the drive motor produces a rotating speed error .sub.i at a certain moment, then for Embodiment 1, the resulting manufacturing error of grating dimension is:

(30) $\begin{array}{cc}{P}_1=R_1{}_i/f& \left(3\right)\end{array}$

(31) According to Equation (2), assuming that the drive motor produces a rotating speed error .sub.i at a certain moment, then for Embodiment 2, the resulting manufacturing error of grating dimension is:

(32) $\begin{array}{cc}{P}_2={\mathrm{KR}}_1{}_i/f& \left(4\right)\end{array}$

(33) Since the reduction ratio K<1 of the large reduction-ratio reducer 9, P.sub.2<P.sub.1. That is, compared with Embodiment 1, Embodiment 2 can provide higher manufacturing accuracy for steel strip grating.

(34) The foregoing is only preferred embodiments of the present disclosure, it should be noted that for those of ordinary skill in the art, without departing from the principles of the present disclosure, certain improvements and retouches may also be made, and these improvements and retouches should also be regarded as the scope of protection of the present disclosure. Each component not specified in the present embodiments may be implemented using prior art.