Permanent magnet alloy laser processing device and processing technology thereof

Abstract

The application discloses a kind of permanent magnet alloy laser processing device and its processing technology, the device includes cabinet, control system and laser cutting system, laser cutting system includes pedestal, laser cutting mechanism, feeding mechanism, clamp, conveying guide rail, pneumatic fragmentation mechanism and discharging mechanism, conveying guide rail is set on pedestal by support mechanism, the laser cutting mechanism is set on pedestal, for laser cutting to sheet, clamp is set on conveying guide rail, for the sheet being laser cutting is clamped, feeding mechanism is set in conveying guide rail one end, for sheet is conveyed to conveying track, pneumatic fragmentation mechanism and discharging mechanism are set behind laser cutting mechanism.The cutting process of the application can be controlled by control system under the condition of ensuring quality, according to shape layout, increase material utilization rate, reduce process, reduce energy consumption, fit low-carbon green development mode, improve processing efficiency.

Description

Technical Field

[0001] This invention belongs to the field of permanent magnet material processing technology, and relates to a laser processing device and processing technology for permanent magnet alloys, specifically to a rapid processing device and process for neodymium iron boron materials based on laser cutting technology. Background Technology

[0002] Neodymium iron boron (NdFeB) is a rare-earth material with high coercivity and high energy product, making it an ideal material for manufacturing high-efficiency, small-sized, and lightweight magnetic functional devices. It is currently widely used in many fields, such as electronic products and home appliances.

[0003] With technological advancements, the requirements for cutting NdFeB materials, especially for irregular shapes and high-precision cutting, are becoming increasingly stringent. Traditional NdFeB cutting processes typically employ grinding and slicing methods, requiring multiple pieces of equipment in combination. This results in long processing times and circuits, making it difficult to guarantee dimensional accuracy and leading to low production efficiency. Furthermore, the cumbersome processing methods are energy-intensive, result in low material utilization, and cause significant waste. This approach is extremely inefficient, incurs huge labor and cost burdens, and is unsuitable for mass production.

[0004] Laser cutting technology has been successfully applied in the field of metal cutting. The principle is to use a high-power-density laser beam to irradiate the material to be cut, so that the material is quickly heated to the vaporization temperature, evaporates and forms a hole, and as the beam moves on the material, the hole continuously forms a very narrow kerf, thus completing the cutting of the material.

[0005] Laser cutting of NdFeB magnets has not yet been widely adopted in the market. This is due to the unique characteristics of NdFeB materials, which place stringent demands on laser precision cutting machines and processes. The industry is still in the exploratory stage of cutting technology development. Before designing automated equipment, the cutting process needs to be resolved, thus the application of automated equipment in the market is currently lacking. At present, most laser processing fixtures for NdFeB materials on the electrode sheet market are inefficient and cannot meet production demands. Furthermore, the high heat generated during laser processing can cause magnetic decay in the permanent magnet material, leading to a significant performance degradation that fails to meet application requirements. Therefore, the market urgently needs to develop a high-efficiency, high-precision NdFeB laser cutting process, which can effectively improve the shortcomings of existing traditional processing methods and is of great significance. Summary of the Invention

[0006] To address the shortcomings of traditional cutting processes, this invention provides a laser processing device and process for permanent magnet alloys. This device enables rapid processing of neodymium iron boron materials while ensuring quality. It allows for layout based on shape, increasing material utilization while reducing processes and energy consumption. This laser cutting process aligns with the low-carbon and green development model and improves processing efficiency.

[0007] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A laser processing device for permanent magnet alloys includes a cabinet, a control system, and a laser cutting system installed within the cabinet. The laser cutting system includes a base, a laser cutting mechanism, a feeding mechanism, a clamp, a conveying guide rail, a pneumatic dicing mechanism, and a discharging mechanism. The conveying guide rail is mounted on the base via a support mechanism for conveying sheet materials. The laser cutting mechanism is mounted on the base for laser cutting the sheet materials. The clamp is mounted on the conveying guide rail for holding the sheet materials being laser cut. The feeding mechanism is located at one end of the conveying guide rail for conveying sheet materials one by one onto the conveying guide rail. The pneumatic dicing mechanism and the discharging mechanism are located behind the laser cutting mechanism at the other end of the conveying guide rail.

[0008] Furthermore, the laser cutting mechanism includes an X-axis moving component, a Y-axis moving component, a Z-axis moving component, and a laser cutting head device. The laser cutting head device is positioned directly above the conveying guide rail and is fixedly mounted on the Z-axis moving component. It is controlled by a control system and achieves precise movement and cutting through the X-axis moving component, Y-axis moving component, and Z-axis moving component. A material-supporting cylinder is also provided below the laser cutting head device for pushing the laser-cut sheet.

[0009] Furthermore, the feeding mechanism includes a hopper, a pushing cylinder, and a top-loading cylinder. The hopper is used to stack sheets, and the pushing cylinder is located at the bottom of the hopper to push the bottom sheet. The bottom of the hopper is flush with the end of the conveying guide rail.

[0010] Furthermore, the hopper is composed of four support columns, which are fixed to the support mechanisms on both sides of the lower end. The top material cylinder is fixed to the support mechanisms on both sides and is used to support the stacked sheets in the hopper.

[0011] Furthermore, the support mechanism is symmetrically arranged on both sides, and is respectively fixedly mounted on the first movable plate and the second movable plate at the bottom. The first movable plate and the second movable plate are movably mounted on the bottom guide rail, which is fixed to the base. A width adjustment knob is also provided on the side of the bottom guide rail to adjust the distance between the first movable plate and the second movable plate to accommodate sheets of different sizes.

[0012] Furthermore, the pneumatic dicing mechanism is located behind the laser cutting head device and is used to separate qualified products and waste materials from the cut sheet.

[0013] Furthermore, the discharge mechanism includes a discharge buffer box, a discharge ramp, a receiving box, and a surplus material box. The discharge buffer box is located below the pneumatic splitting mechanism to buffer the discharge of qualified products. The discharge ramp is inclined at 30° and connects the discharge buffer box and the receiving box. The surplus material box is located behind the pneumatic splitting mechanism, below the end of the conveying guide rail.

[0014] Preferably, the laser cutting system is configured with two parallel workstations to improve processing efficiency.

[0015] The processing technology of the aforementioned permanent magnet alloy laser processing device includes the following steps: Step 1: Arrange the corresponding shape of the product on the control system display and set the laser cutting parameters according to the parameter table; Step 2: Manually place the sheet products into the hopper, and adjust the size of the hopper using the width adjustment knob to accommodate different product sizes; Step 3: The pushing cylinder pushes the bottom sheet of the hopper onto the conveying guide rail and transports it to the laser cutting position. The top cylinder supports the remaining material, and the pushing cylinder retracts and resets. Step 4: The fixture at the cutting position clamps the sheet to be cut, and the laser cutting head cuts out the target shape according to the product cutting path; Step 5: After cutting, the product does not fall off. It is automatically moved to the unloading area by the material support cylinder. The pneumatic splitting mechanism presses the product into the receiving box. Repeat the operation. When the receiving box is full, it can be replaced manually. The remaining edge material is pushed into the scrap box.

[0016] Advantages and features of the process described in this invention: 1. Non-contact processing, and the energy and speed of the high-energy laser beam are adjustable, thus enabling a variety of processing purposes; 2. It can process a variety of metals and non-metals, especially materials with high hardness, high brittleness and high melting point; 3. There is no "tool" wear and no "cutting force" acting on the workpiece during laser processing; 4. During laser processing, the laser beam has high energy density and fast processing speed. Furthermore, it is a localized process with little or no impact on areas not irradiated by the laser. Therefore, the heat-affected zone is small, workpiece thermal deformation is minimal, and subsequent processing is less required. 5. It can perform various processing on workpieces inside sealed containers through transparent media; 6. Because laser beams are easy to guide and focus, and can be changed in various directions, they are very easy to cooperate with CNC systems to process complex workpieces, making it an extremely flexible processing technology. 7. Laser processing offers high production efficiency, reliable quality, and good economic benefits.

[0017] Compared with the prior art, the technical solution provided by this invention has the following advantages: The cutting method of the present invention can increase material utilization while reducing processes and energy consumption by controlling the layout according to the shape, while ensuring quality, through the control system. This aligns with the low-carbon and green development model. The entire process, from feeding, conveying, cutting, to collecting, is fully automated, improving processing efficiency. By reasonably setting the laser processing parameters and controlling the material loss and the integration of the product with the frame during laser processing, the energy during laser processing can be reasonably controlled, so that the magnetic properties of the magnetic products are minimized while meeting the yield requirements (because if the heat is too high, the magnetic properties of the magnetic products will decay, resulting in a significant decrease in magnetic properties; if the heat is too low, it will be difficult to unload the material, leading to missing corners in the product). Attached Figure Description

[0018] Figure 1 This is an overall view of the laser cutting processing device of the present invention; Figure 2-5 This is an internal structural diagram of the laser cutting system of the present invention; In the diagram: 1. Cabinet; 2. Control system; 3. Base; 4. Laser cutting mechanism; 41. X-axis moving assembly; 42. Y-axis moving assembly; 43. Z-axis moving assembly; 44. Laser cutting head device; 5. Feeding mechanism; 51. Hopper; 52. Pushing cylinder; 53. Top cylinder; 6. Fixture; 7. Conveying guide rail; 8. Pneumatic splitting mechanism; 9. Support mechanism; 10. Material support cylinder; 11. First moving plate; 12. Second moving plate; 13. Bottom guide rail; 14. Width adjustment knob; 15. Discharge buffer box; 16. Discharge ramp; 17. Receiving box; 18. Residual material box. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be described in detail below. Obviously, the described embodiments are merely some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other implementation methods obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0020] Combined with appendix Figure 1-5 As shown, this invention relates to a laser processing device for permanent magnet alloys. Based on laser cutting technology, it enables rapid processing of neodymium iron boron materials. The device includes a cabinet 1, a control system 2, and a laser cutting system installed inside the cabinet 1. It is an integrated, enclosed structure that can effectively prevent laser and dust leakage. The electrical control box and the cutting work area are isolated to prevent cutting dust from entering the electrical control box and affecting its performance.

[0021] The laser cutting system includes a base 3, a laser cutting mechanism 4, a feeding mechanism 5, a clamp 6, a conveying guide rail 7, a pneumatic dicing mechanism 8, and a discharging mechanism. The conveying guide rail 7 is mounted on the base 3 via a support mechanism 9 and is used to convey the sheet material. The laser cutting mechanism 4 is mounted on the base 3 and is used to laser cut the sheet material. The clamp 6 is mounted on the conveying guide rail 7 and is used to clamp the sheet material being laser cut. The feeding mechanism 5 is located at one end of the conveying guide rail 7 and is used to convey the sheet material piece by piece onto the conveying guide rail 7. The pneumatic dicing mechanism 8 and the discharging mechanism are located behind the laser cutting mechanism 4 at the other end of the conveying guide rail 7. The pneumatic dicing mechanism 8 is used to separate qualified products and waste materials from the cut sheet material.

[0022] The laser cutting mechanism 4 includes an X-axis moving component 41, a Y-axis moving component 42, a Z-axis moving component 43, and a laser cutting head device 44. The laser cutting head device 44 is located directly above the conveying guide rail 7 and is fixedly mounted on the Z-axis moving component 43. It is controlled by the control system 2 and achieves precise moving and cutting through the X-axis moving component 41, the Y-axis moving component 42, and the Z-axis moving component 43. A material support cylinder 10 is also provided below the laser cutting head device 44 for pushing the laser-cut sheet.

[0023] The feeding mechanism 5 includes a hopper 51, a pushing cylinder 52, and a top-loading cylinder 53. The hopper 51 is used to stack sheets. The pushing cylinder 52 is located at the bottom of the hopper 51 and is used to push the bottom sheet. The bottom of the hopper 51 is flush with the end of the conveying guide rail 7. The hopper 51 is composed of four support columns, which are fixed to the support mechanisms 9 on both sides at the lower end. The top-loading cylinder 53 is fixed to the support mechanisms 9 on both sides and is used to support the stacked sheets in the hopper.

[0024] Preferably, the support mechanism 9 is symmetrically arranged on both sides and is fixedly mounted on the first movable plate 11 and the second movable plate 12 at the bottom. The first movable plate 11 and the second movable plate 12 are movably mounted on the bottom guide rail 13, which is fixed to the base 3. A width adjustment knob 14 is also provided on the side of the bottom guide rail 13 to adjust the distance between the first movable plate 11 and the second movable plate 12 to accommodate sheets of different sizes.

[0025] To optimize material discharge, the discharge mechanism includes a discharge buffer box 15, a discharge ramp 16, a receiving box 17, and a waste material box 18. The discharge buffer box 15 is located below the pneumatic splitting mechanism 8 to buffer the discharge of qualified products. The discharge ramp 16 is inclined at 30° and connects the discharge buffer box 15 and the receiving box 17. The waste material box 18 is located behind the pneumatic splitting mechanism 8, below the end of the conveying guide rail 7.

[0026] Preferably, the laser cutting system is a dual-station parallel arrangement, which allows for simultaneous processing at both stations, thereby improving processing efficiency.

[0027] The processing technology of the aforementioned permanent magnet alloy laser processing device, based on laser cutting technology, enables rapid processing of NdFeB materials, including the following steps: S1: Incoming Material Processing 1. Grind the raw material from all four sides (to ensure the dimensional accuracy of the material blocks and meet equipment requirements); 2. Slice the raw material into multiple layers to obtain sheets of the required thickness; 3. The sheet material is ground on both sides to ensure dimensional accuracy; 4. Cleaning and drying, including ultrasonic degreasing and ultrasonic water washing; to prevent oil and impurities present during laser cutting from affecting the product; S2: Parameter determination: 1. Repeatedly verify and collect data; 2. Compare each verification data with the machining data, find the set with the smallest difference, and confirm it as the optimal parameter (the relevant optimal parameters are described below). 3. Create optimal cutting drawings for the product that save on raw materials; S3: Material loading: 1. Before feeding, randomly inspect the sheet materials to check for defects and remove defective products; 2. The size of the hopper can be manually adjusted according to the size of the material sheet; 3. After adjustment, manually put the sheet into the hopper (the hopper can hold 250 pieces at a time). S4: Automatic feeding: 1. The side-mounted material cylinder of the hopper will hold back the excess material above to prevent the material sheet from being unable to push down; 2. The pusher cylinder pushes the bottom piece of material to the area to be cut; 3. After the material sheet in the cutting area is cut, the material support cylinder pushes the two pieces of material backward at the same time. When the cut material sheet reaches the cutting area, the cut material is placed in the unloading area. S5: Sheet cutting: 1. When the sheet material is pushed to the cutting position, the clamp will hold the sheet material in place, and the equipment will begin cutting; 2. Nitrogen gas is continuously blown out before cutting to ensure rapid cooling during cutting and reduce the heat-affected zone. 3. Avoid material loss during the cutting process. If a large amount of material is lost, the parameters need to be adjusted; (excessive energy will reduce magnetic properties). 4. After cutting, gently press the material sheet to ensure the product is firmly attached to the frame and does not easily fall off. Parameter adjustments are also necessary (low energy will make it difficult to cut the material, resulting in chipped corners). 5. The equipment needs to be cleaned regularly to avoid pipe blockage and insufficient nitrogen pressure, which can prevent cooling and cause cracks. S6: Product cutting: 1. After cutting, the equipment will automatically sense and push the material sheet to the unloading area; 2. The pneumatic chipping mechanism is activated by induction and pressurization, and the product falls into the receiving box through the feeding ramp; 3. The top border remains separate from the product; S7: Waste Collection: 1. When the lower sheet is pushed to the unloading area, the edge of the upper sheet will be pushed down into the rear waste bin; 2. Repeat this process until all sheet material processing is completed.

[0028] It should be noted that the specific laser process parameters of this invention, as well as the coordinated operation of various cylinders and fixtures, are controlled by a control system.

[0029] The preferred laser cutting process parameters of this invention are as follows:

[0030] Velocity / mm / s: 70±10; Acceleration / mm / s: 1200±100; Frequency / kHz: 5 Duty cycle / %: 20%; Energy ratio / %: 17%; Pulse width / μs: 40; Focal length: 0.7; Single pulse output / mJ: 10.2; Average power / W: 51; Cutting auxiliary gas: N2; Air pressure / MPa: 0.3±0.1; Solenoid valve coefficient / %: 30±10; Cutting height / mm: 0.75; In summary, the cutting method of this invention can increase material utilization while reducing processes and energy consumption by using a control system to arrange materials according to shape, thus ensuring quality and aligning with a low-carbon and green development model. The entire process, from feeding, conveying, cutting, and collecting, is fully automated, improving processing efficiency. By rationally setting laser processing parameters and controlling material loss and the fit between the product and the frame during laser processing, the energy during laser processing is rationally controlled, minimizing the decrease in magnetic properties of the magnetic product while maintaining a high yield (because excessive heat will cause the magnetic properties of the magnetic product to decay significantly; insufficient heat will make it difficult to cut the material, resulting in missing corners), thus improving the yield.

[0031] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A laser processing device for permanent magnet alloys, characterized in that, The system includes a laser cutting system, a control system (2), and a monitoring mechanism for monitoring the material loss and the combination of the product and the frame scrap during the laser cutting process. The laser cutting system includes a base (3), a laser cutting mechanism (4), a feeding mechanism (5), a clamp (6), a conveying rail (7), a pneumatic splitting mechanism (8), and a discharging mechanism. The conveying rail (7) is set on the base (3) through a support mechanism (9) and is used to convey the sheet. The laser cutting mechanism (4) is set on the base (3) and is used to laser cut the sheet. The clamp (6) is set on the conveying rail (7) and is used to clamp the sheet being laser cut. The feeding mechanism (5) is set at one end of the conveying rail (7) and is used to convey the sheet piece by piece onto the conveying rail (7). The pneumatic splitting mechanism (8) and the discharging mechanism are set behind the laser cutting mechanism (4) and at the other end of the conveying rail (7). The pneumatic splitting mechanism is used to separate the product and the frame scrap from the cut sheet. The laser cutting mechanism (4) includes an X-axis moving component (41), a Y-axis moving component (42), a Z-axis moving component (43), and a laser cutting head device (44). The laser cutting head device (44) is located directly above the conveying guide rail (7). The laser cutting head device (44) is fixedly mounted on the Z-axis moving component (43). It is controlled by the control system (2) and achieves precise moving and cutting through the X-axis moving component (41), the Y-axis moving component (42), and the Z-axis moving component (43). A material support cylinder (10) is also provided below the laser cutting head device (44) for pushing the laser-cut sheet. The feeding mechanism (5) includes a hopper (51), a pushing cylinder (52), and a top cylinder (53). The hopper (51) is used to stack sheets. The pushing cylinder (52) is located at the bottom of the hopper (51) and is used to push the bottom sheet. The bottom of the hopper (51) is flush with the end of the conveying guide rail (7). The support mechanism (9) is symmetrically arranged on both sides and is fixedly installed on the first movable plate (11) and the second movable plate (12) at the bottom. The first movable plate (11) and the second movable plate (12) are movably arranged on the bottom guide rail (13). The bottom guide rail (13) is fixed on the base (3). A width adjustment knob (14) is also provided on the side of the bottom guide rail (13) to adjust the distance between the first movable plate (11) and the second movable plate (12) to accommodate sheets of different sizes. The discharge mechanism includes a discharge buffer box (15), a discharge ramp (16), a receiving box (17), and a waste box (18). The discharge buffer box (15) is located below the pneumatic splitting mechanism (8) to buffer the discharge of qualified products. The discharge ramp (16) is set at a 30° angle and connects the discharge buffer box (15) and the receiving box (17). The waste box (18) is located behind the pneumatic splitting mechanism (8) and below the end side of the conveying guide rail (7).

2. The permanent magnet alloy laser processing device according to claim 1, characterized in that, The hopper (51) is composed of 4 support columns, which are fixed on the support mechanisms (9) on both sides respectively. The top material cylinder (53) is fixed on the support mechanisms (9) on both sides and is used to support the stacked sheets in the hopper (51).

3. The permanent magnet alloy laser processing device according to claim 1, characterized in that, The laser cutting system is configured with two parallel workstations to improve processing efficiency.

4. A processing technology for a permanent magnet alloy laser processing device, implemented using the permanent magnet alloy laser processing device as described in any one of claims 1-3, characterized in that, The process includes the following steps: S1: Incoming Material Processing (1) The raw materials are finely ground on all four sides; (2) The raw material is sliced ​​into multiple strips to obtain a sheet of the required thickness; (3) Grind the sheet on both sides to ensure the dimensional accuracy of the sheet; (4) Cleaning and drying, including ultrasonic degreasing and ultrasonic water washing; S2: Parameter determination: (1) Repeatedly verify and collect verification data; compare each verification data with the machining data, find the set of verification data with the smallest difference, and confirm it as the optimal parameter; (2) Create the optimal cutting drawings for the product that save raw materials; S3: Sheet feeding: (1) Before feeding, randomly inspect the sheets to see if there are any defects and remove the defective products; (2) The size of the hopper should be manually adjusted according to the size of the sheet; (3) After adjustment, manually put the sheet into the hopper; S4: Automatic feeding: (1) The top material cylinder on the side of the hopper will hold back the excess sheet material above to prevent the sheet material from being pushed down and unable to pass; (2) The pusher cylinder pushes the bottom sheet to the area to be cut; S5: Sheet cutting: (1) When the sheet is pushed to the cutting area, the sheet is clamped by the clamp and the laser cutting mechanism starts cutting. Nitrogen gas is continuously blown out before cutting to ensure rapid cooling during cutting and reduce heat impact. The material loss and the bonding between the product and the edge scrap are monitored during the laser cutting process, and the cutting process parameters are adjusted accordingly to avoid excessive heat causing a significant decrease in the magnetic properties of the product. And situations where the material is difficult to cut due to excessively low heat, resulting in chipped corners in the product; (2) After the sheet material in the cutting area is cut, the material support cylinder pushes the cut sheet material to the unloading area, and the sheet material to be cut is pushed to the cutting area. S6: Product cutting: The pneumatic splitting mechanism is activated by sensing and pressing down, and the product in the cut sheet finally falls into the receiving box, while the edge material remains on top and separates from the product; S7: Waste Collection: (1) When the next piece of sheet material that has been cut is pushed to the unloading area, the edge residue of the previous piece of sheet material that has been cut will be pushed into the rear residue box. (2) Repeat the process to complete the processing.

5. The processing technology of the permanent magnet alloy laser processing device according to claim 4, characterized in that, Nitrogen gas is used as a protective gas during laser cutting.

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