Laser Piercing Beam Offset for Molten Metal Direction Control
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Solution Overview
Problem
During laser processing of sheet metal, molten metal scattering direction is random, leading to adhesion issues and reduced yield due to uneven distribution, causing processing defects and requiring excessive space between products.
Innovation Solution
A processing program creation device and method to control the scattering direction of molten metal by displacing the laser beam's irradiation position using a galvano scanner unit, ensuring the molten metal is scattered in a desirable direction, thereby reducing adhesion and increasing yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pierced hole is formed at a position sufficiently away from the product to prevent molten metal adhesion, then processing defects are reduced, but the maximum number of products that can be cut out cannot be increased and yield cannot be increased
Solution Approach 1:
The patent changes the parameter of laser beam irradiation position by displacing it from the center of the nozzle opening using a galvano scanner unit. This parameter change controls the scattering direction of molten metal, allowing the pierced hole to be formed closer to the product while preventing adhesion, thus increasing yield without sacrificing processing stability
Solution Approach 2:
The patent introduces dynamic control of the laser beam position through the galvano scanner unit, which can adjust the irradiation position in real-time. This dynamic adjustment enables precise control of molten metal scattering direction, resolving the contradiction between maintaining processing stability and increasing productivity
2Reliability
If the laser beam is displaced to control molten metal scattering direction, then molten metal adhesion on the product is minimized, but device complexity increases due to the galvano scanner unit
Solution Approach 1:
The patent utilizes the galvano scanner unit, which is already present in the laser processing machine for other functions, to additionally control the laser beam irradiation position for piercing processing. This multi-functional use avoids adding dedicated complex equipment while achieving control of molten metal scattering direction
Solution Approach 2:
The control device uses the existing galvano scanner unit's capabilities to self-regulate the laser beam position and control molten metal scattering. The system leverages its own existing components to solve the adhesion problem without requiring external complex equipment
3Stability of the object's composition
If assist gas is applied uniformly to molten metal, then the molten metal is uniformly scattered, but for thick sheet metal the molten metal becomes non-uniform in distribution and scatters in random directions
Solution Approach 1:
The patent changes the parameter of laser beam irradiation position to compensate for the non-uniform molten metal distribution caused by thick sheet metal. By displacing the irradiation position, the system controls the scattering direction of the non-uniform molten metal, achieving predictable and controlled scattering patterns even when uniform distribution cannot be maintained
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
The controlled scattering direction minimizes molten metal adhesion on the product, allowing for closer placement of products and reducing processing defects, thus enhancing the efficiency and stability of the laser processing machine.
Implementation Method 1
a processing program creation device and method to control the scattering direction of molten metal by displacing the laser beam's irradiation position using a galvano scanner unit
Implementation Method 2
the assist gas is blown onto the sheet metal through a periphery of the laser beam
Implementation Method 3
molten metal generated by the laser beam
Data Source
AI summary
An optimum scattering angle calculator (213) calculates an optimum scattering angle at which molten metal is most desirably scattered at a time of piercing processing of opening a pierced hole in a sheet metal to fabricate a first product, the molten metal being not adhered to an approach path and not adhered to a processing path for a second product positioned within a search region centered on a center of the pierced hole at the optimum scattering angle. A program creator (214) creates a processing program by adding an auxiliary code to a code for cutting the sheet metal and fabricating the first product, the auxiliary code indicating that, at a time of the piercing processing on the first product, a position of a laser beam in an opening of a nozzle attached to a tip end of a processing head is displaced in an angle direction of the optimum scattering angle from a center of the opening, the laser beam being emitted from the opening.