Automation1

By Aerotech, Inc.

Advanced laser synchronization is not a one-size-fits-all solution; it requires adaptable modes to match specific processing needs. Aerotech’s Automation1 controller offers several sophisticated PSO modes to cater to diverse material processing applications: On/Off Mode: The most fundamental PSO mode, where the laser is toggled on or off based on absolute position coordinates. This is heavily used in high-density drilling operations, such as microvia drilling in electronics manufacturing or through-glass via (TGV) drilling for semiconductor advanced packaging. Window Mode: This synchronization mode restricts laser firing to specific positional "windows" along a trajectory. The laser is armed to fire only when the motion system enters the predefined coordinate window and is disabled upon exiting. This is highly effective for raster scanning applications, laser marking, and selective laser sintering (SLS), ensuring that no optical energy is wasted or deposited outside the target zone. Distance mode: Distance mode refers to fixed distance firing using Position Synchronized Output (PSO) technology. Unlike traditional control methods that rely on fixed frequencies or time-based triggers, this mode links the laser's output trigger directly to the high-resolution position feedback of individual motion axes. Because laser firing is executed based strictly on the actual distance traveled, the system ensures consistent spot spacing and precise fluence control, regardless of any variations in the motion platform's velocity or acceleration. This precise, distance-based coordination is essential for maintaining strict dimensional tolerances and consistency in demanding applications like micromachining. Furthermore, integrating certain lasers—such as mode-locked ultrafast lasers or Q-switched Nd:YAG lasers—presents a unique synchronization challenge. These lasers possess their own internal clocks and fixed pulse repetition frequencies. To achieve true synchronization, the PSO system must align its distance-based trigger with the laser's internal clock. The Automation1 controller manages this by calculating the required pulse delay, holding the positional trigger for a fraction of a millisecond until it perfectly aligns with the laser's next available optical pulse, ensuring maximum energy transfer and beam stability. The Automation1 controller employs an Emulated Quadrature Divider (EQD), which automatically manages data rate differences and matches resolutions across all participating axes. This ensures that the high-frequency signals from a linear motor stage and the ultra-high-frequency signals from a galvo scanner are processed seamlessly into a single, cohesive laser trigger.