Beam Axis Calibration Using Dual-Side Contour Measurement
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Solution Overview
Problem
Beam processing machines face challenges in maintaining precise spatial orientation of the beam axis due to misalignments, which can occur during operation, affecting machining accuracy and requiring frequent recalibration.
Innovation Solution
A method involving a test workpiece with two surfaces, where contour sections are cut from both sides to determine spatial positions, allowing for the calculation and correction of beam axis deviations using a measuring element, enabling semi-automated adjustment of rotation axes and ensuring accurate alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual recalibration of the beam axis is performed, then alignment accuracy can be restored, but time consumption and human error increase
Solution Approach 1:
The system performs self-calibration by automatically detecting contour sections, calculating deviations, and adjusting beam axis parameters without human intervention. The control device autonomously processes measurement data and modifies positioning parameters to restore alignment accuracy.
Solution Approach 2:
The system uses a feedback loop where the measuring means detects actual beam axis positions, the control device compares these with target positions, calculates deviations, and automatically adjusts parameters to eliminate errors, continuously maintaining alignment accuracy.
2Measurement precision
If manual recalibration of the beam axis is performed, then alignment accuracy can be restored, but susceptibility to human error increases
Solution Approach 1:
The system eliminates human intervention in the recalibration process by automatically performing all measurement, calculation, and adjustment operations, thereby removing the source of human error and increasing reliability.
Solution Approach 2:
The system replaces manual mechanical adjustment operations with automated electronic control and measurement systems, substituting human operators with machines that provide consistent, error-free execution of calibration procedures.
3Loss of time
If automated adjustment of rotation axes is implemented, then recalibration time is reduced, but system complexity increases
Solution Approach 1:
The control device serves multiple functions: it controls the beam processing machine, operates the measuring means, calculates deviations, and adjusts positioning parameters. This multi-functionality reduces the need for separate dedicated calibration equipment, managing system complexity while enabling automation.
Solution Approach 2:
The system combines the control device, measuring means, and adjustment mechanisms into an integrated calibration system that operates as a unified automated process, reducing overall system complexity through consolidation while maintaining automation capabilities.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for partial automation of axis adjustments, reducing the time and error associated with manual recalibration, improving machining precision and maintaining optimal beam alignment.
Implementation Method 1
cutting contour sections with a processing beam into a test workpiece
Implementation Method 2
detecting the contour sections with the measuring means from one side of the test workpiece to determine the spatial position of the contour sections
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
In a method for determining a deviation of a spatial orientation of a beam axis (S) of a beam machining machine from a spatial nominal orientation (SO) of the beam axis (S), contour sections (KAI, KB2) are cut into a test workpiece (31) from two sides with a machining beam (5), the contour sections (KAI, KB2) extending parallel to a nominal orientation of an axis of rotation (B, C) to be calibrated. The contour sections (KA1, KA2) are detected, especially scanned, with a measuring means from one side in order to determine the spatial position of the contour sections (KA1, KB1), and the deviation of the spatial orientation of the beam axis (S) of the beam machining machine from the spatial nominal orientation (S0) is determined on the basis of the spatial positions of the contour sections (KA1, KB1).