Dynamic Laser Beam Shaping for High-Speed Cutting Quality
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Solution Overview
Problem
Existing laser cutting technologies face challenges in optimizing productivity and quality, as higher feed rates often compromise cutting quality due to the energy distribution of the laser beam.
Innovation Solution
A computer-implemented method for determining dynamic laser beam shapes during laser cutting, using a laser cutting machine equipped with an optical module for varying the laser beam shape. The method involves receiving a cutting plan, accessing a shape storage with multiple dynamic laser beam shapes, and automatically calculating the allocation of these shapes to specific cutting segments based on workpiece properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the feed rate of the laser cutting head is increased to improve productivity, then productivity increases, but cutting quality deteriorates due to insufficient energy distribution
Solution Approach 1:
The patent applies dynamic beam shaping (DBS) that modifies laser beam properties (spot size, intensity distribution, shape) in real-time during the cutting process. The beam characteristics are dynamically adjusted based on the cutting segment type, material properties, and feed rate, allowing the system to maintain optimal energy distribution even at higher feed rates, thus resolving the contradiction between productivity and cutting quality
Solution Approach 2:
The system changes multiple laser beam parameters simultaneously (spot size, intensity distribution, beam shape, focal position) to optimize the energy coupling with the material. By adjusting these parameters according to the specific cutting segment and material properties, the system maintains effective cutting conditions across varying feed rates, preventing quality deterioration while preserving productivity gains
2Use of energy by moving object
If a smaller spot size is used to concentrate laser energy, then energy density increases, but kerf dimensions become insufficient for proper melt ejection
Solution Approach 1:
The system dynamically adjusts the beam diameter and intensity distribution during cutting. For thick materials, it transitions from a small concentrated spot to a larger distributed beam pattern, enabling sufficient kerf width for melt ejection while maintaining adequate energy density through increased total power or optimized intensity profiles, thus resolving the contradiction between energy concentration and kerf dimensions
Solution Approach 2:
The patent employs 3D dynamic beam shaping that modifies the laser beam in multiple dimensions (横向 and 纵向 intensity distributions, focal depth). This allows the system to create complex three-dimensional energy distributions within the material, achieving both sufficient kerf width for ejection and adequate energy density for effective cutting by utilizing spatial dimensionality rather than relying solely on spot size reduction
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 enhances cutting quality by allowing for segment-specific dynamic laser beam shapes, improving kerf dimensions, preventing heat accumulation, and optimizing energy distribution, thereby achieving better productivity and quality in laser cutting.
Implementation Method 1
laser cutting by means of a laser cutting machine... transforming absorbed laser energy into heat, to melt material
Implementation Method 2
transforming absorbed laser energy into heat
Data Source
AI summary
A control unit for determining a dynamic laser beam shape for controlling a laser cutting machine, which is provided with a dynamic beam shaping module for varying the shape of the laser beam. The control unit includes a cutting plan interface, which is configured for receiving a cutting plan, an interface to a shape storage with a stored set of dynamic laser beam shapes, in particular more than two, and a processor which is configured for automatically calculating for each of the cutting segments an allocation to a dynamic laser beam shape of the set of dynamic laser beam shapes, wherein calculating the allocation is based on the property indicator of the workpiece and is specific for the respective cutting segment. The processor is further configured for providing control instructions for controlling the laser cutting machine by applying the determined dynamic laser beams shapes for each cutting segment specifically.