Flexible Laser Manufacturing System with Networked Station Control

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Solution Overview

Problem

Existing laser processing systems lack efficient control and management of multiple stations in a networked configuration, leading to suboptimal production rates and flexibility in material processing tasks.

Innovation Solution

A flexible laser manufacturing system with an array of interconnected laser processing stations, each equipped with a controller that monitors and manages the processing status and sends instructions to optimize production rates, allowing dynamic reconfiguration and redistribution of tasks across stations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple laser processing stations are arranged in a networked configuration, then productivity and processing capacity are improved, but system complexity and control difficulty increase

Engineering Contradiction:

Improveproduction rateVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system is divided into multiple independent laser processing stations, each capable of autonomous operation. Each station can be individually controlled and monitored, allowing the system to scale from single-station to multi-station configurations without requiring complete system redesign.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The controller is designed to universally manage multiple laser processing stations through a standardized interface. The same controller hardware and software can monitor and control any number of stations, eliminating the need for different control systems for different station counts.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If laser processing stations are arranged in an arrayed configuration, then flexibility in task distribution is improved, but control and management complexity increase

Engineering Contradiction:

ImproveflexibilityVSAvoidcontrol complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system dynamically assigns processing tasks to available stations based on real-time status and capability matching. When stations are added or removed from the array, the controller automatically reconfigures task distribution without manual intervention, maintaining optimal flexibility regardless of array size.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The controller continuously monitors the status of each laser processing station and uses this feedback to make real-time decisions about task allocation. This closed-loop control allows the system to adapt to changing conditions while maintaining simple, rule-based decision logic.

Inventive Principle:

Principle #23Feedback

3Productivity

If multiple laser processing stations are used, then processing capacity scales with demand, but monitoring and managing all stations becomes more difficult

Engineering Contradiction:

Improveprocessing capacityVSAvoidease of monitoring

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The controller consolidates monitoring and management functions for all laser processing stations into a single unified interface. Operators can view and control multiple stations through one system, eliminating the need to separately monitor each station and simplifying operations as the system scales.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Each laser processing station autonomously reports its own status and capabilities to the controller, and the controller automatically makes task allocation decisions based on this information. This self-reporting mechanism reduces the monitoring burden on operators while maintaining comprehensive system visibility.

Inventive Principle:

Principle #25Self-service

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 efficient and flexible material processing by optimizing production rates, scaling capacity according to demand, and maintaining productivity during maintenance by dynamically reallocating tasks across the networked stations.

Implementation Method 1

a laser source configured to generate a laser beam for processing a target material

Methodology Applied

Scientific EffectLaser: Laser

Data Source

PatentUS9354630B2Flexible laser manufacturing systems and associated methods of use and manufacture

Publication Date: 2016.05.31 UNIVERSAL LASER SYSTEMS INC

AI summary

Embodiments of flexible laser manufacturing systems are disclosed herein. A flexible laser manufacturing system configured in accordance with one embodiment includes a plurality of laser processing stations. Each laser processing station can include a laser source configured to generate a laser beam for processing target material, and a first controller coupled to the laser source. The flexible laser manufacturing system also includes a second controller coupled to the first controller of the individual laser processing stations. The second controller is configured to monitor and instruct each of the first controllers for processing target material of each of the corresponding laser processing stations.