Fiber Laser and Plasma Metal Processing for Low-Maintenance 3D Cutting
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Solution Overview
Problem
Current metal cutting and welding technologies, particularly CO2 laser systems, face high maintenance costs due to alignment and cleaning issues with mirrors, leading to production downtimes and increased expenses, while lacking versatility in cutting thicker materials and requiring separate equipment for different processes.
Innovation Solution
A multi-functional machine integrating a high-precision CNC system with a fiber optic laser for cutting and welding, and a plasma source for cutting thicker metals, allowing for seamless switching between laser and plasma cutting heads, and featuring a robot arm for 3D welding, enabling cutting of various metals and pipes with improved efficiency and reduced maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If CO2 laser systems with mirrors are used for metal cutting, then cutting quality and speed are improved, but maintenance costs increase and production downtimes occur due to mirror alignment and cleaning requirements
Solution Approach 1:
The patent extracts and removes the mirrors from the laser beam delivery system, replacing them with a fiber optic cable that directly transmits the laser beam from the CO2 laser source to the cutting head. This elimination of mirrors resolves the technical contradiction by maintaining high cutting speed while eliminating the maintenance and alignment issues that cause production downtime.
Solution Approach 2:
The patent replaces the mechanical mirror alignment system with an optical fiber transmission system. The fiber optic cable substitutes for the mechanical mirrors and alignment mechanisms, providing a more reliable and maintenance-free method of delivering the laser beam to the cutting head, thereby reducing production downtime.
2Productivity
If CO2 laser systems with mirrors are used for metal cutting, then cutting quality and speed are improved, but maintenance costs increase due to mirror cleaning and replacement
Solution Approach 1:
The patent extracts and removes the mirrors from the laser beam delivery system, replacing them with a fiber optic cable that directly transmits the laser beam from the CO2 laser source to the cutting head. This elimination of mirrors resolves the technical contradiction by maintaining high cutting speed while eliminating the maintenance and alignment issues that cause production downtime.
Solution Approach 2:
The patent employs a fiber optic cable that is more durable and maintenance-free compared to mirrors. The fiber optic transmission system replaces the fragile mirrors that require periodic cleaning and replacement, thereby reducing maintenance costs while maintaining high productivity.
3Manufacturing precision
If laser cutting is used for metal processing, then cutting quality is improved, but cutting depth is limited and depends on laser power
Solution Approach 1:
The patent creates a multi-functional cutting system that can operate in two modes: laser cutting for high-precision work on thinner materials, and plasma cutting for deeper cuts on thicker materials. The system universally handles both cutting methods through a single machine platform, allowing users to switch between laser and plasma modes depending on the material thickness and quality requirements.
Solution Approach 2:
The patent introduces a plasma cutting system as an intermediary solution for thick material cutting. When laser cutting reaches its depth limitation, the system switches to plasma cutting mode, which uses a plasma arc instead of a laser beam to achieve deeper cuts, thereby extending the overall cutting capability of the system.
4Adaptability or versatility
If separate laser and plasma cutting systems are used for different material thicknesses, then cutting versatility is improved, but device complexity and space requirements increase
Solution Approach 1:
The patent merges the laser cutting system and plasma cutting system into a single integrated machine. Both cutting systems share common components such as the worktable, control system, and safety enclosure. The laser source and plasma generator are housed in the same machine structure, allowing users to switch between cutting methods without requiring separate equipment, thereby reducing overall system complexity and space requirements.
Solution Approach 2:
The patent creates a multi-functional cutting system that can operate in two modes: laser cutting for high-precision work on thinner materials, and plasma cutting for deeper cuts on thicker materials. The system universally handles both cutting methods through a single machine platform, allowing users to switch between laser and plasma modes depending on the material thickness and quality requirements.
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 machine significantly reduces maintenance costs and production downtimes by eliminating the need for mirror alignment and cleaning, enables cutting and welding of diverse metals with high precision and quality, and supports both thin and thick metal processing with a single system, enhancing industrial productivity and flexibility.
Implementation Method 1
fiber laser
Implementation Method 2
The same fiber optic produces the laser radiation so that the laser output enters directly in the cutting head
Implementation Method 3
an electric arc is formed through the nozzle which makes it possible for the gas to pass to the fourth state of matter, plasma. The plasma is sufficiently hot to melt the metal
Implementation Method 4
an electric arc is formed through the nozzle
Data Source
AI summary
System for 2D and 3D metal processing with fiber optic laser and plasma, that includes CNC for cutting metal plates with fiber optic laser and plasma and a robot arm for cutting and welding metals with fiber optic laser. The system is characterized because it includes three processes in one single equipment: metal cutting with fiber optic laser, metal cutting with plasma and metal welding with fiber optic laser. The equipment has a computer numerical control (CNC) system and a working area of 1200×3000 mm for cutting metals; it has two cutting heads, one for fiber optic laser and one for plasma as well as one 360° rotating robot arm on which the laser welding head or the laser cutting head can be placed for 3D welding, or cutting circular or rectangular pipes, respectively.