Ionizer Control for Plasma Charge in Laser Beam Machining
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Solution Overview
Problem
In laser beam cutting machining, the generation of plasma leads to rough machined surfaces and adhesion of dross due to the close proximity of the nozzle and workpiece, making it difficult to set optimal machining conditions.
Innovation Solution
A machining condition adjustment device that utilizes a high-flow speed assist gas to reduce plasma generation and neutralizes the plasma charge using an ionizer, which adjusts its settings based on measured plasma charge to improve cutting quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If the nozzle is positioned close to the workpiece to increase gas pressure, then the assist gas pressure on the workpiece is improved, but plasma generation increases causing rough surfaces and dross adhesion
Solution Approach 1:
An ionizer is introduced as an intermediary device between the laser beam machining process and the workpiece. The ionizer generates ions that neutralize the plasma charge, preventing plasma-related defects while allowing the nozzle to maintain close positioning for effective assist gas pressure.
Solution Approach 2:
The harmful plasma charge is extracted and neutralized by the ionizer, separating the beneficial assist gas pressure effect from the harmful plasma generation effect. This allows the system to maintain high gas pressure without suffering from plasma-induced surface quality degradation.
2Productivity
If high-speed cutting is performed with close nozzle-workpiece distance, then cutting speed is improved, but plasma generation causes rough surfaces and dross adhesion
Solution Approach 1:
The ionizer serves as a mediator that enables high-speed cutting by neutralizing plasma charge. This allows the system to maintain the close nozzle-workpiece positioning necessary for high-speed cutting while eliminating plasma-related surface quality issues.
Solution Approach 2:
The plasma, which was previously harmful causing rough surfaces and dross adhesion, is converted into a neutral state by the ionizer. The plasma generation itself is not eliminated, but its harmful charged effects are neutralized, transforming the situation from harmful to beneficial.
3Productivity
If plasma is generated during machining, then material removal is achieved, but the charged plasma causes rough surfaces and dross adhesion
Solution Approach 1:
The ionizer introduces ions as an intermediary substance that neutralizes the plasma charge. This allows material removal via plasma generation to continue while the harmful charged effects are eliminated through charge neutralization.
Solution Approach 2:
The electrical charge parameter of the plasma is changed from charged to neutral by the ionizer. This parameter change eliminates the harmful effects of plasma charge while preserving the material removal capability of the plasma.
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 solution effectively reduces plasma generation and improves cutting quality by neutralizing the plasma charge, preventing adhesion and enhancing the machined surface finish.
Implementation Method 1
neutralizes the plasma by detecting an amount of the generated plasma and radiating an opposite electric charge to the detected amount (amount of charge) of the generated plasma
Implementation Method 2
a shock wave is generated from a mouth of the nozzle 6 so as to form a wall, which re-converges the assist gas 7 so as to maximize a flow speed of the assist gas 7
Data Source
AI summary
A machining condition adjustment device adjusts settings of an ionizer so as to neutralize a charge carried by plasma generated during laser beam machining of a workpiece by a laser beam machining device, calculates an amount of charge per unit time that is to be radiated from the ionizer, based on the amount of charge carried by the plasma generated during the laser beam machining, and sets the ionizer to radiate the calculated amount of charge per unit time.