Laser Cutting Head Nozzle Alignment with Digital Gauge Referencing
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Solution Overview
Problem
In laser machining systems, the relative positions of the laser machining beam and the process gas jet often become misaligned due to nozzle changes or over time, leading to suboptimal machining results.
Innovation Solution
A method and apparatus that utilize digital gauges with probes to contact the process gas nozzle, a position device with a pad and rod to align indicators along the X and Y axes, and adjustment screws to align the gas jet nozzle with the laser beam axis, facilitated by a controller subroutine that determines and corrects the alignment by cutting a sacrificial hole and measuring its center.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual alignment methods are used to adjust the gas jet nozzle, then the alignment process can be completed, but the alignment accuracy is insufficient and operator skill level significantly affects results
Solution Approach 1:
The patent replaces manual mechanical alignment methods with an automated system using digital indicators, controllers, and computer-generated alignment subroutines. The system automatically measures and calculates nozzle misalignment and directs adjustment, eliminating dependence on operator skill and achieving consistent high-precision alignment results.
Solution Approach 2:
The alignment system performs self-measurement and self-correction by using digital indicators to automatically detect nozzle position, the controller to calculate misalignment, and the alignment subroutine to guide adjustments. This self-service capability eliminates the need for skilled operators to perform subjective visual assessments and manual adjustments.
2Adaptability or versatility
If frequent nozzle changes are performed, then different nozzles can be used for different machining requirements, but alignment must be repeatedly adjusted increasing time consumption
Solution Approach 1:
The patent establishes a standardized mounting interface with predefined alignment references that prepare the system for rapid re-alignment. The digital indicators are pre-positioned and the controller is pre-programmed with alignment subroutines, so when nozzles are changed, the system can quickly re-measure and re-align without manual setup, significantly reducing adjustment time.
Solution Approach 2:
The system continuously monitors nozzle position using digital indicators and provides real-time feedback to the controller. After nozzle changes, the controller automatically executes alignment subroutines that measure the new nozzle position and calculate required adjustments, enabling rapid iterative correction and minimizing the time needed to achieve proper alignment.
3Reliability
If traditional alignment methods are used, then the process can be completed, but the alignment is not repeatable and machining quality varies
Solution Approach 1:
The patent replaces subjective manual alignment with an automated measurement and control system using digital indicators, a controller with alignment subroutines, and computer-calculated adjustment directions. This systematic approach ensures that the same alignment procedure is consistently applied every time, achieving high repeatability and consistent machining quality regardless of which operator performs the alignment.
Solution Approach 2:
The alignment process is segmented into distinct automated steps: digital indicators measure nozzle position, the controller calculates misalignment, the alignment subroutine generates adjustment instructions, and the operator follows standardized adjustment steps. This segmentation of the alignment process into standardized, measurable steps ensures repeatable results and consistent machining quality.
Data Source
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AI summary
An alignment tool (60) for a laser machine tool (20) includes a frame (62) that is mountable to the laser cutting head (28) of the laser machine tool (20); a first indicator (64A) mounted to the frame (62) along an X-axis; a second indicator (64B) mounted to the frame (62) along a Y-axis; a position device (58) mounted to the frame (62), the position device (58) operable to reference upon a surface (28A) of the laser cutting head (28) to align the first indicator (64A) along an X-axis of the laser cutting head (28), and to align the second indicator (64B) along a Y-axis of the laser cutting head (28); and a fastener (80) mounted to the frame (62), the fastener (80) operable to retain the frame (62) to the laser cutting head (28).