A laser cutting machine adaptive partition dust removal system, method, terminal and medium

Abstract

The application belongs to the technical field of laser cutting machine dust removal, and specifically discloses a laser cutting machine adaptive partition dust removal system, method, terminal and medium. The system comprises four wind channel arrays integrated in the machine tool bed body, which are divided into a left upper blowing channel, a right upper suction channel, a left lower suction channel and a right lower suction channel; a plurality of air port combinations are arranged on each wind channel; each air port combination is provided with a driving structure for independently controlling the opening and closing of airflow; and a cooperative control unit. The cooperative control unit obtains the current working platform state and real-time cutting parameters, calculates the smoke dust transverse diffusion field, and dynamically schedules the opening number of the air port combination and the operation frequency of the fan in the corresponding coordinate interval. The application constructs an independent heterogeneous dust removal flow field for the upper and lower exchange platforms, realizes precise smoke exhaust following, and cooperates with the heat insulation suspension support structure in the bed body to effectively prevent the machine tool from being deformed by heat while greatly reducing the overall energy consumption of dust removal.

Description

Technical Field

[0001] This invention belongs to the field of dust removal technology for laser cutting machines, specifically relating to an adaptive zoned dust removal system, method, terminal, and medium for laser cutting machines. Background Technology

[0002] As the manufacturing industry moves towards higher efficiency and greener practices, high-power laser cutting machines are increasingly widely used in metal processing. To improve processing efficiency, existing medium and large-sized cutting machines generally adopt an "upper and lower exchange platform" structure to achieve uninterrupted loading and unloading operations. However, laser cutting generates a large amount of high-temperature and harmful fumes, necessitating the installation of efficient dust removal and fume extraction systems to meet the environmental protection requirements of modern industry.

[0003] Existing laser cutting machine dust removal systems mostly adopt a dual-suction mode located at the bottom of the machine bed. When the machine is using the lower worktable for cutting, the cutting point is relatively close to the bottom suction port, which can still play a certain role in dust removal.

[0004] However, when the equipment switches to cutting on the upper worktable, there is a certain height difference between the cutting point and the bottom air intake, which means that the negative pressure field at the bottom cannot effectively cover the upper cutting area. This causes the smoke and dust generated at the top to not be sucked in time and easily disperses to the surrounding areas of the factory. Summary of the Invention

[0005] This invention addresses the problems in the prior art by providing an adaptive zoned dust removal system, method, terminal, and medium for laser cutting machines. This solves the problem in the background art where a height difference exists between the cutting point and the bottom air intake when using an "upper and lower exchange platform" structure to achieve uninterrupted loading and unloading operations. This results in the negative pressure field at the bottom not being able to effectively cover the upper cutting area, and the generated dust not being sucked up in time, easily escaping in large quantities to the surrounding area of ​​the factory.

[0006] The technical solution adopted in this invention is as follows: In a first aspect, this application provides an adaptive zoned dust removal system for a laser cutting machine, comprising: The four-channel air duct array is integrated inside the machine tool bed, including the upper left air blowing duct, the upper right air suction duct, the lower left air suction duct, and the lower right air suction duct; Multiple air blowing combinations are evenly distributed along the length of the upper left air blowing duct, and the upper right air suction duct has an equal number of upper right air suction combinations. The air blowing combinations and the upper right air suction combinations are arranged opposite to each other on the left and right sides of the bed. Multiple lower left suction assemblies are evenly distributed along the length of the lower left suction duct, and the lower right suction duct has an equal number of lower right suction assemblies as the lower left suction assemblies; the lower left suction assemblies and the lower right suction assemblies are located below the cutting surface of the lower working platform, and the two are symmetrically arranged in both height and horizontal direction. The dynamic partition execution unit includes air outlets arrayed on the blowing assembly, the upper right suction assembly, the lower left suction assembly, and the lower right suction assembly, respectively. Each air outlet assembly is equipped with an independent drive structure to control the opening and closing of the airflow. The collaborative control unit includes a position sensor network set on the upper and lower exchange platforms for identifying the working status, a smoke sensor set on the cutting beam, and a controller that communicates with each of the air outlet combinations and the corresponding dust removal fan of each air duct. The controller calculates the smoke and dust diffusion field based on real-time cutting parameters, and dynamically schedules the number of air outlets to be opened and the operating frequency of the dust removal fan corresponding to each air duct within the corresponding coordinate interval, in conjunction with the feedback platform position and smoke concentration.

[0007] Furthermore, the independent drive structure of the air vent assembly includes: A cylinder mounting plate fixed on the corresponding air duct, a cylinder mounted on the cylinder mounting plate, and a sealing plate connected to the cylinder extension rod; The sealing plate is fitted onto the positioning rod through round holes on both sides to achieve sliding guidance, and a sealing plate rubber is fixed on the sealing plate for airtight cooperation with the opening of the air duct under the drive of the cylinder.

[0008] Furthermore, the four-channel array is suspended and supported by multiple intermediate partitions set in the inner cavity of the bed; The intermediate partition is made of heat-insulating material.

[0009] Secondly, this application provides an adaptive zone dust removal method for laser cutting machines, using the adaptive zone dust removal system for laser cutting machines as described in the first aspect, the method comprising the following steps: Step S1: Obtain the target platform currently in working state through the position sensor network, and obtain the real-time processing parameters of the CNC system. The processing parameters include the real-time coordinates of the cutting head, the average laser power, the plate thickness, the nozzle outlet air pressure, and the cutting speed. Step S2: Substitute the real-time processing parameters into the preset diffusion model to calculate the lateral diffusion distance of the smoke and dust generated under the current working conditions; Step S3: If the target platform is the upper working platform, the upper convection tracking strategy is executed. The misalignment offset is calculated based on the lateral diffusion distance of the smoke and dust, and the air outlets of the corresponding sections of the upper left blowing duct and the upper right suction duct are coordinated to open. If the target platform is the lower working platform, then the lower negative pressure tracking strategy is executed, and the air outlets of the corresponding sections of the lower left air intake duct and the lower right air intake duct are scheduled to open synchronously and symmetrically. Step S4: Calculate the total number of air outlet combinations that need to be turned on in the current decision, estimate the total required air volume based on the nominal air volume of a single air outlet, linearly map it to the target operating frequency of the dust collector fan, and synchronously output the switching command to the independent drive structure of the corresponding air outlet combination and the frequency command to the dust collector fan.

[0010] Furthermore, in step S2, the formula for calculating the lateral diffusion distance of the smoke and dust is:

[0011] in, This represents the lateral diffusion distance of the smoke and dust. The average power of the laser. For the thickness of the sheet metal, This refers to the nozzle outlet air pressure. For cutting speed, This is based on the preset material coefficients of the processed materials.

[0012] Furthermore, in step S3, the upper-layer convection tracking strategy specifically includes: Calculate the crossflow offset distance caused by the airflow affecting the smoke and dust, and convert this distance into the air outlet offset that needs to be staggered between the upper left blowing duct and the upper right suction duct; The basic opening range is determined with the X-axis coordinate of the cutting head as the center; Obtain the Y-axis coordinate of the cutting head. If the Y-axis coordinate is located in the left region, activate the corresponding blowing combination within the basic activation range and increase the air outlet offset to the right to activate the corresponding upper right suction combination. If the Y-axis coordinate is in the middle area, the corresponding blowing combination and the upper right suction combination will be turned on synchronously and the air outlet offset will be maintained. If the Y-axis coordinate is located in the right region, then the corresponding upper right suction combination within the basic opening range is activated, and the corresponding blowing combination is activated to the left. The lower-level negative pressure tracking strategy specifically includes: Calculate the effective capture radius of a single air outlet on the lower working platform, and combine it with the overlap efficiency coefficient to obtain the joint capture equivalent radius; Based on the lateral diffusion distance of the smoke and dust and the equivalent radius of the joint capture, calculate the minimum number of air vents required to be opened on one side. An initial interval is determined with the X-axis coordinate of the cutting head as the center. If the number of air vents in the initial interval is less than the minimum number of air vents, the interval is expanded to the minimum number of air vents on both sides with the cutting point as the center. Within the calculated final range, the left and right lower air intake ducts are controlled to simultaneously activate the left and right lower air intake combinations with the same number on both sides to construct a symmetrical negative pressure field.

[0013] Furthermore, the formula for calculating the crossflow offset distance is as follows:

[0014] in, This is the crossflow offset distance. The crossflow coefficient is a preset value; the air outlet offset is the value obtained by dividing the crossflow offset distance by the spacing of the air outlet combination on the same side and rounding it down. The formula for calculating the effective capture radius of a single air outlet is:

[0015] in, To effectively capture the radius, For reference capture radius, For reference height, The vertical height from the cutting surface of the lower working platform to the opening of the suction assembly. This represents the actual air volume of a single air outlet. For reference air volume.

[0016] Furthermore, the method also includes adaptive correction logic based on working state switching and environmental feedback: When the position sensor network detects a layer switch between the upper and lower working platforms, the control system keeps the suction fan corresponding to the upper working layer running for a preset delay time to suck up residual suspended dust. After the delay time is over, the dust removal system of the new working layer is started. The controller reads the concentration data of the smoke sensor in real time. When the smoke concentration exceeds the preset threshold, it automatically expands the opening range of the air vent combination to both sides. When the smoke concentration is continuously lower than the lower threshold for a set time, it shrinks the opening range of the air vent combination without reducing the number of vents to the minimum set.

[0017] Thirdly, this application provides a terminal, including: The memory is used to store the adaptive zone dust removal program of the laser cutting machine; A processor is used to implement the steps of the adaptive zone dust removal method for laser cutting machines as described in the second aspect when executing the adaptive zone dust removal program for the laser cutting machine.

[0018] Fourthly, this application provides a computer-readable storage medium that stores computer instructions. When a computer reads the computer instructions in the storage medium, the computer executes the adaptive zone dust removal method for laser cutting machines as described in the second aspect.

[0019] As can be seen from the above technical solutions, the advantages of the present invention are: By integrating a four-channel array inside the machine tool bed to correspond to the upper and lower platforms, and by dynamically scheduling the number of air vents and the fan frequency in the corresponding coordinate range based on sensor status and real-time cutting parameters, precise dust removal in different zones at different heights of the upper and lower exchange platforms is achieved, and the overall operating energy consumption of the dust removal system is effectively reduced.

[0020] By configuring a cylinder, a sealing plate fitted onto the positioning rod, and sealing plate rubber for the independent drive structure of the air outlet assembly, smooth sliding guidance when the air outlet is opened and reliable sealing when closed are achieved, which can effectively prevent negative pressure leakage from the air outlet in non-working areas.

[0021] By using a partition made of heat-insulating material to suspend and support the four-channel air duct array within the machine bed cavity, physical isolation between the exhaust duct and the main body of the machine bed is achieved. This can block the heat conduction of high-temperature hot smoke and dust to the machine bed, prevent thermal expansion and deformation of the machine bed, and maintain the machining accuracy of the machine tool.

[0022] By reading the machining parameters of the CNC system in real time to calculate the dust diffusion distance, and then distributing the air vent opening command and the corresponding fan frequency conversion command to different working layers, a closed-loop adaptive matching between the dust removal system's suction capacity and the actual dust generation scale is achieved, which can significantly reduce the power consumption caused by blindly running the fan at full load.

[0023] By establishing a multivariate fluid dynamics model that includes average laser power, plate thickness, nozzle outlet air pressure, and cutting speed, the lateral diffusion distance of smoke and dust is calculated. This enables precise quantification of the actual impact range of smoke and dust under different cutting conditions and provides data support for the dynamic delineation of the damper opening range.

[0024] By calculating the crossflow offset of smoke and dust caused by airflow, and combining it with the dynamic adjustment of the staggered opening state of the blowing and suction combinations based on the Y-axis coordinate of the cutting head, a transverse convection air curtain that accurately tracks the cutting point can be constructed above the working platform, effectively overcoming the problem of smoke and dust dispersion during long-distance airflow transportation.

[0025] By introducing the crossflow coefficient and real-time process parameters to calculate the crossflow offset distance and convert it into the number offset of the air outlet, the accurate prediction and compensation of the deviation of the smoke and dust movement trajectory during the air curtain blowing process is realized, which can ensure that the airflow of the air outlet accurately guides the smoke and dust into the air intake on the opposite side.

[0026] By calculating the effective capture radius of a single air vent and the equivalent radius of the combined capture, the minimum number of air vents required to be opened is determined. By strictly controlling the synchronous and symmetrical opening of the suction combination on the left and right sides, a balanced local negative pressure cavity is constructed below the lower working platform, which can prevent smoke and dust from overflowing from one side edge due to the imbalance of the negative pressure field. Attached Figure Description

[0027] To more clearly illustrate the technical solution of the present invention, the accompanying drawings used in the description will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0028] Figure 1 This is a partial structural schematic diagram of the adaptive zoned dust removal system for a laser cutting machine according to an embodiment of the present invention; Figure 2 This is a schematic diagram of the upper left air duct structure in an embodiment of the present invention; Figure 3 This is a flowchart of the adaptive zone dust removal method for laser cutting machines according to an embodiment of the present invention.

[0029] In the diagram: 10101, lower left air intake duct; 10102, upper left air blowing duct; 10103, upper right air intake duct; 10104, lower right air intake duct; 101051, cylinder; 101052, cylinder fixing plate; 101053, sealing plate; 101054, sealing rubber; 101055, maintenance plate; 101056, positioning rod; 101057, air blowing sheet metal. Detailed Implementation

[0030] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0031] Please see Figure 1 and Figure 2 As shown, this application provides an adaptive zoned dust removal system for a laser cutting machine, comprising: The four-air duct array is integrated inside the machine tool bed, including the upper left air blowing duct 10102, the upper right air suction duct 10103, the lower left air suction duct 10101, and the lower right air suction duct 10104. In practice, the sheet metal exterior of the machine tool provides a relatively stable, windless dust removal environment for the dust removal system, helping to prevent smoke and dust from escaping. The aforementioned four independent main air ducts are integrated inside the machine bed. These four 12-meter-long ducts constitute the main exhaust network of the system, providing independent and non-interfering airflow transmission channels for the upper and lower double-layer working platforms. Multiple blowing combinations are evenly distributed along the length of the upper left blowing duct 10102, and an equal number of upper right suction combinations are evenly distributed on the upper right suction duct 10103. The blowing combinations and the upper right suction combinations are arranged opposite each other on the left and right sides of the machine bed. In a specific embodiment, for a cutting range of 12 meters, 16 blowing combinations are evenly arranged on the upper left blowing duct 10102, and 16 upper right suction combinations are also evenly arranged on the upper right suction duct 10103. When the upper worktable is performing cutting operations, the system adopts a convection blowing and suction dust removal mode. The blowing combinations on the left and the upper right suction combinations on the right are activated in pairs. Since the blowing and suction ports are basically at the same height as the cutting point of the upper worktable, a horizontal air curtain that penetrates the cutting area can be formed above the cutting surface. As soon as the smoke and dust are generated, they are blown to the right and sucked into the air duct, effectively preventing secondary diffusion of the upper smoke and dust. Multiple lower left suction assemblies are evenly distributed along the length of the lower left suction duct 10101, and the number of lower right suction assemblies is equal to that of the lower left suction assemblies evenly distributed on the lower right suction duct 10104; the lower left suction assemblies and the lower right suction assemblies are located below the cutting surface of the lower working platform, and the two are symmetrically arranged in both height and horizontal direction. In practical implementation, within a 12-meter cutting range, 12 lower left suction combinations are evenly arranged on the lower left suction duct 10101, and 12 lower right suction combinations are also evenly arranged on the lower right suction duct 10104. These 24 lower-level air outlet combinations are located 0.38m below the lower cutting plane. When the lower worktable is working, the system adopts a dual-duct suction mode, that is, suction combinations with the same number on both sides must be opened simultaneously. Thanks to the relatively sealed structure formed between the lower worktable and the bed material cart, this symmetrical synchronous suction can quickly form a balanced negative pressure chamber below it, effectively preventing smoke and dust from escaping from one side. The dynamic partition execution unit includes air outlet combinations arrayed on the blowing combination, the upper right suction combination, the lower left suction combination, and the lower right suction combination, respectively. Each air outlet combination is equipped with an independent drive structure to control the opening and closing of the airflow. In a specific embodiment, each of the 32 upper-layer combinations and 24 lower-layer combinations is equipped with an independent drive structure, enabling individual control of each air vent. In actual operation, the system does not need to open all the air vents on one side; instead, it dynamically determines which air vent combinations within a specific numbered range to open based on the current coordinates of the cutting point. This dynamic zoning control allows the system to meet the current local dust removal airflow requirements, minimizing the energy consumption of the dust removal fans and the overall equipment while ensuring dust removal efficiency. The collaborative control unit includes a network of position sensors on the upper and lower exchange platforms for identifying the working status, a smoke sensor on the cutting beam, and a controller that communicates with the independent drive structure of each air vent combination and the corresponding dust removal fan in each air duct. In practical implementation, the position sensor network comprises eight sensors. The upper platform is equipped with sensors for the upper cutting zone deceleration, upper cutting zone positioning, upper picking zone deceleration, and upper picking zone positioning. Similarly, the lower platform is equipped with four sensors for the lower cutting zone deceleration, lower cutting zone positioning, lower picking zone deceleration, and lower picking zone positioning. During the equipment's self-test upon startup, the sensor signals confirm the positions of the upper and lower platforms, identifying whether the workbench is currently in the "upper cutting zone in position" or "lower cutting zone in position" state, and thus determining whether the dust removal system should activate the lower or upper dust removal system. Furthermore, a smoke sensor is installed on the cutting beam to monitor the environmental conditions above the cutting zone in real time. Based on this sensor feedback, the PLC controller sends switching commands to the solenoid valve assembly to control the action of cylinder 101051 and sends frequency commands to the dust collector inverter. The controller calculates the smoke diffusion field based on real-time cutting parameters and, combined with the feedback platform position and smoke concentration, dynamically schedules the number of air vents opened within the corresponding coordinate range and the operating frequency of the corresponding dust collector fans in each air duct.

[0032] In a specific embodiment, the exhaust power of the dust removal system adaptively adjusts based on process parameters such as the thickness of the cutting material, the laser power used, the nozzle air pressure, and the cutting speed. The controller calculates the lateral diffusion distance and crossflow offset distance of the smoke in real time using a built-in algorithm, thereby accurately determining the minimum number of vents required to open and their specific numbering range. After calculating the total number of vents required for the current decision, the controller calculates the total required air volume and linearly maps it to a target frequency of 20Hz to 50Hz, adjusting the speed of the dust removal variable frequency fan by outputting a 4-20mA signal. If the smoke concentration reported by the smoke sensor exceeds the standard, the system can automatically expand the opening range of the vents to both sides for adaptive adjustment.

[0033] In practical implementation, this system is mainly applied to laser cutting equipment with upper and lower exchange platforms, such as large-format laser cutting machines with a cutting range of 12 meters × 2.5 meters. Existing dust removal methods, such as dual-suction and follow-through blowing / suction, suffer from problems such as excessive height difference in dust removal and easy smoke overflow when facing upper and lower exchange platforms. This application completely separates the upper and lower worktable dust removal in terms of physical channels and control logic, realizing a mechanism for autonomously adjusting the dust removal position according to the status of the worktable.

[0034] In some embodiments, the independent drive structure of the air outlet assembly includes: a cylinder fixing plate 101052 fixed on the corresponding air duct, a cylinder 101051 mounted on the cylinder fixing plate 101052, and a sealing plate 101053 connected to the cylinder extension rod. In specific implementation, taking the blower assembly as an example, the cylinder fixing plate 101052 is mechanically fixed to the upper left blower duct 10102, and the actuator cylinder 101051 is installed on the cylinder fixing plate 101052 as the power source for opening and closing. The sealing plate 101053, used to block the airflow, is directly fixed to the extension rod of the cylinder 101051. When the system issues a control command, the piston rod of the cylinder 101051 extends or retracts, directly pushing and pulling the sealing plate 101053 to reciprocate against the side wall of the duct, thereby realizing the physical opening or closing operation of the damper channel. The sealing plate 101053 is sleeved on the positioning rod 101056 through round holes on both sides to achieve sliding guidance, and sealing plate rubber is fixed on the sealing plate 101053 for airtight cooperation with the opening of the duct under the drive of the cylinder 101051.

[0035] In a specific embodiment, a long, strip-shaped positioning rod 101056 is fixed to the outer side of the corresponding air duct, and a sealing plate 101053 has pre-drilled round holes on both sides, which are fitted through the positioning rod 101056. When the cylinder 101051 pushes or pulls the sealing plate 101053, the positioning rod 101056 provides a stable and reliable linear sliding guide for the sealing plate 101053, preventing the sealing plate 101053 from shifting or getting stuck. Simultaneously, a dedicated sealing rubber is fixed to the inner side of the sealing plate 101053 facing the air duct. When the cylinder 101051 drives the sealing plate 101053 to the closed position, the sealing rubber is tightly pressed against the outer perimeter of the sheet metal opening of the air duct, ensuring a reliable seal when the damper is closed, effectively preventing air leakage in the main air duct under high negative pressure. In some embodiments, the four-air duct array is suspended and supported by multiple intermediate partitions disposed within the bed cavity; the intermediate partitions are made of heat-insulating material.

[0036] In practice, the four main air ducts, when passing through the inner cavity of the machine bed, are not placed directly against the machine tool base or side wall, but are supported by horizontally distributed intermediate partitions. These partitions have pre-drilled square holes for the air ducts to pass through, allowing the main body of the air ducts to be suspended and supported within the machine tool cavity. Because the intermediate partitions are made of a specially designed heat-insulating material, they possess the physical property of being unable to conduct heat. This structural design effectively cuts off the heat conduction path, greatly reducing the impact of high-temperature laser cutting fumes entering the ducts on the metal machine bed, thereby preventing thermal expansion and deformation of the machine bed. This not only improves the stability of the equipment's processing but also indirectly improves the overall cutting accuracy of the machine.

[0037] Each blower assembly on the upper left blower duct 10102 is equipped with an independent drive structure to precisely control the opening and closing of the airflow at the corresponding air outlet. This independent drive structure and its associated components specifically include: a cylinder 101051, a cylinder fixing plate 101052, a sealing plate 101053, sealing rubber 101054, a maintenance plate 101055, a positioning rod 101056, and a blower sheet metal 101057.

[0038] In the actual assembly structure, the blower sheet metal 101057 and the positioning rod 101056 are both fixedly mounted on the outer wall of the upper left blower duct 10102, forming the basic support frame of the entire actuation mechanism. The cylinder 101051, as the core power actuator, is securely mounted on the upper left blower duct 10102 via the cylinder fixing plate 101052. The sealing plate 101053, used to block or guide airflow, is fixedly connected to the piston extension rod of the cylinder 101051.

[0039] To ensure smooth operation and reliable sealing, the sealing plate 101053 has guide holes on both sides and is fitted onto the positioning rod 101056. When a control command is received, the piston rod of the cylinder 101051 extends or retracts, pushing or pulling the sealing plate 101053 to slide linearly along the positioning rod 101056, effectively preventing deviation and jamming during operation. Simultaneously, the sealing rubber 101054 and the maintenance plate 101055 are both fixedly installed on the sealing plate 101053. When the cylinder 101051 drives the sealing plate 101053 to the closed position, the sealing rubber 101054 on the sealing plate 101053 is tightly pressed against the edge of the air outlet of the blower sheet metal 101057, achieving an absolutely airtight fit at the air outlet and preventing air leakage under high or negative pressure conditions, thereby ensuring the overall energy efficiency and stability of the zoned dust removal system.

[0040] Please see Figure 3 As shown, this application provides an adaptive zone dust removal method for laser cutting machines. Using the aforementioned adaptive zone dust removal system for laser cutting machines, the method includes the following steps: Step S1: Obtain the target platform currently in working state through the position sensor network, and read the real-time processing parameters of the CNC system. The processing parameters include the real-time coordinates of the cutting head, the average laser power, the plate thickness, the nozzle outlet air pressure, and the cutting speed. In a specific embodiment, during system operation, the PLC controller reads the underlying status data of the CNC system in real time via the communication bus. The position sensor network consists of eight sensors installed on the machine tool, with four sensors configured on each of the upper and lower work platforms, respectively used to collect physical signals of platform cutting deceleration, cutting completion, material picking deceleration, and material picking completion. The controller accurately determines whether the upper or lower platform is performing the processing operation based on the cutting completion signal. Simultaneously, the controller continuously acquires real-time process data such as the current average laser power, plate thickness, air pressure, and absolute coordinates of the cutting head at a control cycle of 50ms, providing data input for subsequent fluid dynamics calculations.

[0041] Step S2: Substitute the real-time processing parameters into the preset diffusion model to calculate the lateral diffusion distance of the smoke and dust generated under the current working conditions; In practice, the dust generated by high-power laser cutting is not statically distributed but changes drastically with the processing technology. The controller incorporates dynamic diffusion calculation logic based on the aforementioned real-time processing parameters, eliminating the need for traditional static region division. By calling a preset diffusion model, the system can determine in real time the specific physical distance the dust diffuses laterally from the cutting point to both sides of the machine bed under the combined effects of laser thermal effect, gas impact force, and material thickness. This dynamic distance is the core benchmark for determining how many dust removal dampers need to be opened subsequently.

[0042] Step S3: If the target platform is the upper working platform, the upper convection tracking strategy is executed, the misalignment offset is calculated based on the lateral diffusion distance of the smoke and dust, and the air outlets of the corresponding sections of the upper left blowing duct and the upper right suction duct are scheduled to open in coordination; if the target platform is the lower working platform, the lower negative pressure tracking strategy is executed, and the air outlets of the corresponding sections of the lower left suction duct and the lower right suction duct are scheduled to open synchronously and symmetrically. In a specific embodiment, for a large-format device with a cutting stroke of 12m, 16 air vent combinations are evenly distributed on both the upper left blowing duct and the upper right suction duct. When the upper working platform is detected to be in operation, the system adopts a convection mode. Considering that the blowing airflow will push the smoke and dust to the opposite side, the controller calculates the offset deviation caused by the airflow and causes the numbers of the activated blowing vents on the left and the activated suction vents on the right to be numerically misaligned to accurately catch the smoke and dust. When the lower platform is in operation, since the 12 lower air vent combinations are installed 0.38m below the cutting plane, the system switches to a dual-side suction mode, requiring the suction combinations in the same numbered interval on both the left and right sides to open completely synchronously and symmetrically, quickly establishing a balanced negative pressure field in the sealed cavity to prevent smoke and dust from escaping from one side.

[0043] Step S4: Calculate the total number of air outlet combinations that need to be turned on in the current decision, estimate the total required air volume based on the nominal air volume of a single air outlet, linearly map it to the target operating frequency of the dust collector fan, and synchronously output the switching command to the independent drive structure of the corresponding air outlet combination and the frequency command to the dust collector fan.

[0044] In practice, the controller accumulates the total number of air vent combinations required to be opened by the current command at the end of the calculation. Using a single air vent design exhaust volume of 500 m³ / h and a safety factor of 1.2, the total system air volume requirement is calculated. This total air volume is then proportionally calculated to the maximum capacity of the dust collector fan (16000 m³ / h) and linearly mapped to an operating frequency range of 20Hz to 50Hz. Finally, the controller not only outputs DO switching signals to each solenoid valve group to drive the cylinders but also simultaneously outputs a 4-20mA analog signal to the frequency converter to adjust the suction fan speed. During upper-layer cutting, the blower on the left maintains a fixed frequency of 80%. This achieves an energy saving rate of 75% to 80% in conditions such as cutting thin plates.

[0045] In some embodiments, the formula for calculating the lateral diffusion distance of the smoke and dust in step S2 is:

[0046] in, This represents the lateral diffusion distance of the smoke and dust. The average power of the laser. For the thickness of the sheet metal, This refers to the nozzle outlet air pressure. For cutting speed, This is based on the preset material coefficients of the processed materials.

[0047] In a specific embodiment, the controller internally stores a material coefficient mapping table. For example, when cutting carbon steel, the system calls a coefficient of 0.15; when cutting stainless steel, it calls a coefficient of 0.12; and when cutting aluminum, it calls a coefficient of 0.10. This mechanism takes into account the differences in the vaporization characteristics of different metals. The physical logic shows that the higher the laser power used, the thicker the plate being cut, or the higher the nozzle auxiliary air pressure, the larger the calculated lateral diffusion distance value, and the more air vents the system subsequently instructs to open, thus achieving on-demand dust removal.

[0048] In some embodiments, step S3, the upper-layer convection tracing strategy specifically includes: Calculate the crossflow offset distance caused by the airflow affecting the smoke and dust, and convert this distance into the air outlet offset that needs to be staggered between the upper left blowing duct and the upper right suction duct; The basic opening range is determined with the X-axis coordinate of the cutting head as the center; Obtain the Y-axis coordinate of the cutting head. If the Y-axis coordinate is located in the left region, activate the corresponding blowing combination within the basic activation range and increase the air outlet offset to the right to activate the corresponding upper right suction combination. If the Y-axis coordinate is in the middle area, the corresponding blowing combination and the upper right suction combination will be turned on synchronously and the air outlet offset will be maintained. If the Y-axis coordinate is located in the right region, then the corresponding upper right suction combination within the basic opening range is activated, and the corresponding blowing combination is activated to the left. The lower-level negative pressure tracking strategy specifically includes: Calculate the effective capture radius of a single air outlet on the lower working platform, and combine it with the overlap efficiency coefficient to obtain the joint capture equivalent radius; Based on the lateral diffusion distance of the smoke and dust and the equivalent radius of the joint capture, calculate the minimum number of air vents required to be opened on one side. An initial interval is determined with the X-axis coordinate of the cutting head as the center. If the number of air vents in the initial interval is less than the minimum number of air vents, the interval is expanded to the minimum number of air vents on both sides with the cutting point as the center. Within the calculated final range, the left and right lower air intake ducts are controlled to simultaneously activate the left and right lower air intake combinations with the same number on both sides to construct a symmetrical negative pressure field.

[0049] In a specific embodiment, the system first calculates the effective suction radius based on the nominal airflow of a single air outlet and a fixed vertical drop of 0.38m below. Considering that the negative pressure at the edges will overlap when multiple air outlets are open, the system introduces an overlap efficiency coefficient of 0.65 to derive the combined capture equivalent radius. The controller uses the smoke and dust diffusion distance to calculate the minimum number of air outlets to be opened on one side, and sets a mandatory lower limit of at least 3 and an upper limit of at most 12. If the initial interval defined by the X-axis coordinate is less than the calculated minimum number, the controller will automatically and evenly increase the air outlet numbering towards both ends of the machine tool with the current cutting point as the geometric center until the requirement is met. Finally, the controller synchronously sends signals to the lower left and lower right solenoid valves within the final interval to form a completely symmetrical vacuum suction effect.

[0050] In some embodiments, the formula for calculating the crossflow offset distance is:

[0051] in, This is the crossflow offset distance. The crossflow coefficient is a preset value; the air outlet offset is the value obtained by dividing the crossflow offset distance by the spacing of the air outlet combination on the same side and rounding it down. The formula for calculating the effective capture radius of a single air outlet is:

[0052] in, To effectively capture the radius, For reference capture radius, For reference height, The vertical height from the cutting surface of the lower working platform to the opening of the suction assembly. This represents the actual air volume of a single air outlet. For reference air volume.

[0053] In practical implementation, the crossflow model is specifically used to correct deviations in the upper-level convective airflow trajectory. The system has a built-in crossflow coefficient table, for example, 1.0 for carbon steel, 0.8 for stainless steel, and 0.7 for aluminum. After calculating the physical offset distance, it is divided by the fixed 0.75m spacing between the upper-level air outlets and rounded to the nearest integer, discretizing the continuous distance into integer offsets for the air dampers. For the lower level, the system is preset with a reference capture radius of 0.5m under the conditions of a reference height of 0.1m and a reference airflow of 500m³ / h. Since the actual physical height from the lower cut surface to the air intake reaches 0.38m, the system automatically calculates the true effective capture radius after attenuation under this large drop using a formula, ensuring accurate calculation of negative pressure coverage.

[0054] In some embodiments, the method further includes adaptive correction logic based on working state switching and environmental feedback: When the position sensor network detects a layer switch between the upper and lower working platforms, the control system keeps the suction fan corresponding to the upper working layer running for a preset delay time to suck up residual suspended dust. After the delay time is over, the dust removal system of the new working layer is started. The controller reads the concentration data of the smoke sensor in real time. When the smoke concentration exceeds the preset threshold, it automatically expands the opening range of the air vent combination to both sides. When the smoke concentration is continuously lower than the lower threshold for a set time, it shrinks the opening range of the air vent combination without reducing the number of vents to the minimum set.

[0055] In a specific embodiment, the vertical distance between the upper and lower cutting platforms is 300mm. When the machine tool completes its work and triggers a layer switching, the system forcibly starts a 10-second anti-disturbance timer. During these 10 seconds, the suction system of the original working layer remains open to absorb suspended residual smoke. After the timer expires, the new working layer is activated, avoiding airflow disturbance during the switching process. Simultaneously, the smoke sensor on the crossbeam continuously provides feedback on the concentration. If the detected concentration exceeds the upper limit, the system forcibly adds one vent on each side of the already opened vent area. If the concentration remains below the extremely low lower threshold for 10 consecutive seconds, the system automatically attempts to reduce the number of vents on each side to achieve a contraction, exploring energy consumption extremes while ensuring environmental protection.

[0056] In some embodiments, this application provides a terminal, including: The memory is used to store the adaptive zone dust removal program of the laser cutting machine; A processor is used to execute the steps of the adaptive zone dust removal method for the laser cutting machine when performing the adaptive zone dust removal system for the laser cutting machine.

[0057] In some embodiments, this application provides a computer-readable storage medium that stores computer instructions. When a computer reads the computer instructions in the storage medium, the computer executes the adaptive zone dust removal method for the laser cutting machine.

[0058] The above description is merely a preferred embodiment of one or more embodiments of this specification and is not intended to limit the scope of one or more embodiments of this specification. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of one or more embodiments of this specification should be included within the protection scope of one or more embodiments of this specification.

Claims

1. An adaptive zoned dust removal system for a laser cutting machine, characterized in that, include: The four-air duct array is integrated inside the machine tool bed, including the upper left air blowing duct (10102), the upper right air suction duct (10103), the lower left air suction duct (10101), and the lower right air suction duct (10104). The upper left air duct (10102) has multiple air blowing combinations evenly distributed along its length, and the upper right air suction duct (10103) has an equal number of upper right air suction combinations. The air blowing combinations and the upper right air suction combinations are arranged opposite to each other on the left and right sides of the bed. The lower left suction duct (10101) has multiple lower left suction assemblies evenly distributed along its length, and the lower right suction duct (10104) has an equal number of lower right suction assemblies as the lower left suction assemblies; the lower left suction assemblies and the lower right suction assemblies are located below the cutting surface of the lower working platform, and the two are symmetrically arranged in both height and horizontal direction. The dynamic partition execution unit includes air outlets arrayed on the blowing assembly, the upper right suction assembly, the lower left suction assembly, and the lower right suction assembly, respectively. Each air outlet assembly is equipped with an independent drive structure to control the opening and closing of the airflow. The collaborative control unit includes a position sensor network set on the upper and lower exchange platforms for identifying the working status, a smoke sensor set on the cutting beam, and a controller that communicates with each of the air outlet combinations and the corresponding dust removal fan of each air duct. The controller calculates the smoke and dust diffusion field based on real-time cutting parameters, and dynamically schedules the number of air outlets to be opened and the operating frequency of the dust removal fan corresponding to each air duct within the corresponding coordinate interval, in conjunction with the feedback platform position and smoke concentration.

2. The adaptive zoned dust removal system for laser cutting machines according to claim 1, characterized in that, The independent drive structure of the air outlet assembly includes: A cylinder fixing plate (101052) fixed on the corresponding air duct, a cylinder (101051) installed on the cylinder fixing plate (101052), and a sealing plate (101053) connected to the cylinder extension rod. The sealing plate (101053) is sleeved on the positioning rod (101056) through round holes on both sides to achieve sliding guidance, and the sealing plate (101053) is fixed with sealing plate rubber for airtight cooperation with the opening of the air duct under the drive of the cylinder (101051).

3. The adaptive zoned dust removal system for laser cutting machines according to claim 1, characterized in that, The four-channel airflow array is suspended and supported by multiple intermediate partitions set in the inner cavity of the bed. The intermediate partition is made of heat-insulating material.

4. An adaptive zone dust removal method for a laser cutting machine, using the adaptive zone dust removal system for a laser cutting machine as described in any one of claims 1-3, characterized in that, Includes the following steps: Step S1: Obtain the target platform currently in working state through the position sensor network, and obtain the real-time processing parameters of the CNC system. The processing parameters include the real-time coordinates of the cutting head, the average laser power, the plate thickness, the nozzle outlet air pressure, and the cutting speed. Step S2: Substitute the real-time processing parameters into the preset diffusion model to calculate the lateral diffusion distance of the smoke and dust generated under the current working conditions; Step S3: If the target platform is the upper working platform, the upper convection tracking strategy is executed. The misalignment offset is calculated based on the lateral diffusion distance of the smoke and dust, and the air outlets of the corresponding sections of the upper left blowing duct and the upper right suction duct are coordinated to open. If the target platform is the lower working platform, then the lower negative pressure tracking strategy is executed, and the air outlets of the corresponding sections of the lower left air intake duct and the lower right air intake duct are scheduled to open synchronously and symmetrically. Step S4: Calculate the total number of air outlet combinations that need to be turned on in the current decision, estimate the total required air volume based on the nominal air volume of a single air outlet, linearly map it to the target operating frequency of the dust collector fan, and synchronously output the switching command to the independent drive structure of the corresponding air outlet combination and the frequency command to the dust collector fan.

5. The adaptive zone dust removal method for laser cutting machines according to claim 4, characterized in that, In step S2, the formula for calculating the lateral diffusion distance of the smoke and dust is: in, This represents the lateral diffusion distance of the smoke and dust. The average power of the laser. For the thickness of the sheet metal, This refers to the nozzle outlet air pressure. For cutting speed, This is based on the preset material coefficients of the processed materials.

6. The adaptive zone dust removal method for laser cutting machines according to claim 4, characterized in that, In step S3, the upper-layer convection tracing strategy specifically includes: Calculate the crossflow offset distance caused by the airflow affecting the smoke and dust, and convert this distance into the air outlet offset that needs to be staggered between the upper left blowing duct and the upper right suction duct; The basic opening range is determined with the X-axis coordinate of the cutting head as the center; Obtain the Y-axis coordinate of the cutting head. If the Y-axis coordinate is located in the left region, activate the corresponding blowing combination within the basic activation range and increase the air outlet offset to the right to activate the corresponding upper right suction combination. If the Y-axis coordinate is in the middle area, the corresponding blowing combination and the upper right suction combination will be turned on synchronously and the air outlet offset will be maintained. If the Y-axis coordinate is located in the right region, then the corresponding upper right suction combination within the basic opening range is activated, and the corresponding blowing combination is activated to the left. The lower-level negative pressure tracking strategy specifically includes: Calculate the effective capture radius of a single air outlet on the lower working platform, and combine it with the overlap efficiency coefficient to obtain the joint capture equivalent radius; Based on the lateral diffusion distance of the smoke and dust and the equivalent radius of the joint capture, calculate the minimum number of air vents required to be opened on one side. An initial interval is determined with the X-axis coordinate of the cutting head as the center. If the number of air vents in the initial interval is less than the minimum number of air vents, the interval is expanded to the minimum number of air vents on both sides with the cutting point as the center. Within the calculated final range, the left and right lower air intake ducts are controlled to simultaneously activate the left and right lower air intake combinations with the same number on both sides to construct a symmetrical negative pressure field.

7. The adaptive zone dust removal method for laser cutting machines according to claim 6, characterized in that, The formula for calculating the crossflow offset distance is: in, This is the crossflow offset distance. The crossflow coefficient is a preset value; the air outlet offset is the value obtained by dividing the crossflow offset distance by the spacing of the air outlet combination on the same side and rounding it down. The formula for calculating the effective capture radius of a single air outlet is: in, To effectively capture the radius, For reference capture radius, For reference height, The vertical height from the cutting surface of the lower working platform to the opening of the suction assembly. This represents the actual air volume of a single air outlet. For reference air volume.

8. The adaptive zone dust removal method for laser cutting machines according to claim 4, characterized in that, The method also includes adaptive correction logic based on working state switching and environmental feedback: When the position sensor network detects a layer switch between the upper and lower working platforms, the control system keeps the suction fan corresponding to the upper working layer running for a preset delay time to suck up residual suspended dust. After the delay time is over, the dust removal system of the new working layer is started. The controller reads the concentration data of the smoke sensor in real time. When the smoke concentration exceeds the preset threshold, it automatically expands the opening range of the air vent combination to both sides. When the smoke concentration is continuously lower than the lower threshold for a set time, it shrinks the opening range of the air vent combination without reducing the number of vents to the minimum set.

9. A terminal, characterized in that, include: The memory is used to store the adaptive zone dust removal program of the laser cutting machine; A processor is configured to implement the steps of the adaptive zone dust removal method for a laser cutting machine as described in any one of claims 4-8 when executing the adaptive zone dust removal device for the laser cutting machine.

10. A computer-readable storage medium, characterized in that, The storage medium stores computer instructions. When the computer reads the computer instructions in the storage medium, the computer executes the adaptive zone dust removal method for laser cutting machines as described in any one of claims 4-8.

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