Cutting Velocity Profile Control for Material Waste Reduction
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Solution Overview
Problem
Conventional cutting systems require manual adjustments for lead in and lead out profiles, leading to inefficiencies and inaccuracies, as well as increased cycle times due to potential miscalculations in achieving and maintaining cutting velocity, resulting in unnecessary material waste and scrap edges.
Innovation Solution
A system that calculates and controls lead in and lead out profiles based on the cutting velocity, material type, and geometric coordinates to precisely manage the acceleration and deceleration of the cutting implement, ensuring accurate cutting operations and minimizing waste by automatically adjusting these profiles in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustments for lead in and lead out profiles are used, then ease of operation is maintained, but manufacturing precision and productivity deteriorate due to inefficiencies and inaccuracies
Solution Approach 1:
The system automatically calculates and adjusts lead in and lead out profiles based on cutting velocity, material type, and geometric coordinates without requiring manual intervention. The controller performs real-time calculations to determine optimal acceleration and deceleration parameters, enabling the system to self-regulate cutting precision parameters.
Solution Approach 2:
The system uses real-time feedback from cutting parameters (velocity, material type, geometric coordinates) to dynamically adjust lead in and lead out profiles. The controller continuously monitors cutting conditions and modifies acceleration/deceleration profiles to maintain optimal cutting precision throughout the operation.
2Productivity
If manual adjustments for lead in and lead out profiles are used, then device complexity is reduced, but loss of time increases due to miscalculations and extended cycle times
Solution Approach 1:
The system pre-calculates lead in and lead out profiles based on known cutting parameters (velocity, material type, geometric coordinates) before the cutting operation begins. This preliminary calculation ensures optimal acceleration and deceleration schedules are established in advance, eliminating time losses during actual cutting due to miscalculations or adjustments.
Solution Approach 2:
The system dynamically adjusts lead in and lead out profiles in real-time based on changing cutting conditions. The controller continuously optimizes acceleration and deceleration parameters during the cutting operation, allowing the system to adapt to varying speeds and material properties, thereby reducing cycle times while maintaining productivity.
3Loss of substance
If manual adjustments for lead in and lead out profiles are used, then ease of operation is maintained, but material waste increases due to scrap edges from inaccurate velocity control
Solution Approach 1:
The system automatically calculates and adjusts lead in and lead out profiles to ensure precise velocity control throughout the cutting operation. By self-regulating the acceleration and deceleration parameters based on cutting velocity, material type, and geometric coordinates, the system eliminates scrap edges caused by manual miscalculations, thereby reducing material waste without requiring complex manual adjustments.
4Manufacturing precision
If automatic calculation and control of lead in and lead out profiles is implemented, then manufacturing precision and productivity are improved, but device complexity increases
Solution Approach 1:
The controller is designed to perform multiple functions: managing power output to the torch, controlling voltage and current output, calculating lead in and lead out profiles, and adjusting cutting velocity. By consolidating these diverse functions into a single multi-functional controller, the system achieves high manufacturing precision without proportionally increasing overall device complexity.
Data Source
AI summary
The system and method described herein generally pertains to generating a lead in profile that defines acceleration before a cutting velocity is achieved to perform a cutting operation and a lead out profile that defines deceleration after the cutting operation is performed. The lead in profile defines acceleration from approximately zero (0) to the cutting velocity within a duration of time in order to perform the cutting operation, wherein the lead in profile is calculated based on the cutting velocity or a type of material of the workpiece, a start location for the cutting operation, and a thickness of the workpiece. The lead out profile defines deceleration from the cutting operation to approximately zero (0) within a duration of time, wherein the lead out profile is calculated based on the cutting velocity or a type of material of the workpiece, an end location for the cutting operation, and a thickness of the workpiece.