Compound Fiber Laser Cutting for Variable Workpiece Thickness
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Solution Overview
Problem
Current laser cutting machines are inefficient in processing workpieces of varying thicknesses, as they require complex refitting or multiple machines to achieve the necessary focal diameters for high-quality cutting, which is not economical or rapid.
Innovation Solution
A laser cutting method using a compound fiber with multiple parallel, non-concentric fibers of different cross-sectional sizes and shapes, allowing for selective coupling of unprocessed laser beams to produce processing laser beams with varying characteristics, such as beam quality, power, and focal diameter, depending on the workpiece thickness, without the need for machine refitting or transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large focal diameter is used to cut thick workpieces, then the cutting gap is sufficiently wide to blow out slag, but the beam quality deteriorates and processing speed decreases
Solution Approach 1:
The patent implements dynamic switching between different fiber bundles (small focal diameter for thin sheets, large focal diameter for thick sheets) based on workpiece thickness. This allows the system to adapt its focal characteristics in real-time, maintaining high processing speeds for thin materials while achieving adequate cutting quality for thick materials without permanent mechanical refitting.
Solution Approach 2:
The system changes the focal diameter parameter by selectively coupling laser beams into different fiber bundles with varying core diameters. This parameter change is achieved through optical switching mechanisms that redirect the laser beam to appropriate fibers, enabling the same machine to process both thin and thick workpieces optimally.
2Productivity
If a small focal diameter is used to process thin workpieces rapidly, then processing speed increases, but the cutting gap becomes too narrow to effectively remove slag from thick workpieces
Solution Approach 1:
The system dynamically selects between small and large focal diameter fiber bundles based on the detected workpiece thickness. For thin workpieces, the small focal diameter fibers enable rapid processing, while for thick workpieces, the system switches to large focal diameter fibers to ensure adequate slag removal and cutting quality.
Solution Approach 2:
The fiber bundle is segmented into multiple sub-bundles with different focal characteristics (small and large focal diameters). This segmentation allows the system to select the appropriate segment for the current processing task, optimizing both speed and quality based on workpiece thickness without requiring complete machine refitting.
3Adaptability or versatility
If laser processing machines are refitted to handle different workpiece thicknesses, then the machine can process both thin and thick sheets, but the complexity and cost of refitting increases disproportionately
Solution Approach 1:
The patent creates a universal laser processing machine that can handle both thin and thick workpieces using a single integrated system. The compound fiber structure with multiple fiber bundles of different focal diameters, combined with optical switching mechanisms, enables one machine to perform multiple functions (processing various thicknesses) without requiring separate specialized machines or complex mechanical refitting.
Solution Approach 2:
The patent introduces an intermediary optical switching system that mediates between the laser source and the workpiece. This switching mechanism selectively connects the laser beam to appropriate fiber bundles based on workpiece thickness, serving as an intelligent intermediary that enables versatility without direct mechanical refitting of the entire machine.
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
Enables reliable, high-quality, and rapid cutting of workpieces with different thicknesses using a single machine, maintaining a complete processing range with a more compact and lighter construction, and allowing for higher processing speeds.
Implementation Method 1
selectively coupling one or more unprocessed laser beams into one or more of a plurality of parallel, non-concentric fibers of a compound fiber
Data Source
AI summary
A method for cutting workpieces of different thicknesses includes providing at least one unprocessed laser beam, selectively forming a processing laser beam from the at least one unprocessed laser beam in accordance with a thickness of the workpiece, and cutting the workpiece with the processing laser beam. Forming the processing laser beam includes selectively coupling one or more unprocessed laser beams into one or more of a plurality of parallel, non-concentric fibers of a compound fiber, the plurality of fibers of the compound fiber having different cross-sectional shapes. A laser beam characteristic of the processing laser beam exiting the compound fiber differs depending upon which fibers of the compound fiber receive the at least one unprocessed laser beam, the laser beam characteristic of the processing laser beam differing depending on the thickness.