Laser Beam Shape Transitions for Burr-Free Cutting Contours
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Solution Overview
Problem
Existing laser cutting technologies face challenges in maintaining high quality and flexibility when using dynamic laser beam shaping due to abrupt transitions between different beam shapes, leading to issues like contour errors, burrs, and melt expulsion.
Innovation Solution
A method and system for determining transition phases between consecutive dynamic laser beam shapes, using a dynamic laser beam shaping module and neural networks to optimize the transition times and shapes based on cutting segments and material properties, minimizing abrupt changes and enhancing cutting quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dynamic laser beam shaping is used to optimize cutting quality and flexibility, then cutting quality and adaptability are improved, but abrupt transitions between different beam shapes cause contour errors, burrs, and melt expulsion
Solution Approach 1:
The patent applies preliminary action by calculating and defining transition phases between different dynamic laser beam shapes before the actual cutting process. The control unit determines the sequence of beam shapes and calculates transition phases in advance, ensuring smooth transitions without abrupt changes that would cause contour errors, burrs, and melt expulsion. This preparatory calculation of transition phases eliminates the harmful effects while maintaining the benefits of dynamic beam shaping.
2Stability of the object's composition
If static beam shaping is used, then the laser beam is provided before treatment starts with a stable profile, but the beam shape cannot be changed during processing, reducing flexibility
Solution Approach 1:
The patent applies dynamics by enabling the laser beam shape to change during processing through dynamic laser beam shaping. The system uses a dynamic beam shaping module that can modify the beam shape in real-time based on the cutting requirements. The control unit calculates transition phases to ensure these changes occur smoothly, combining the stability of predefined beam shapes with the flexibility of dynamic adjustment during the cutting process.
3Productivity
If the transition time between consecutive dynamic laser beam shapes is set to 0 for maximum productivity, then processing speed is maximized, but abrupt transitions occur causing quality issues
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting the transition time parameter between consecutive laser beam shapes. The control unit calculates optimal transition phases that balance the transition duration with productivity requirements. By modifying the transition time parameter appropriately - not setting it to zero but optimizing it based on the specific beam shape changes required - the system maintains high processing speed while avoiding abrupt transitions that would compromise cutting quality.
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 method improves cutting quality by reducing contour errors, minimizing burrs and melt expulsion, and ensuring smooth transitions, thereby enhancing the overall cutting performance and flexibility.
Implementation Method 1
laser cutting by means of a laser cutting machine, which is provided with at least one optical module, e.g., a dynamic laser beam shaping module, for dynamically varying the shape of the laser beam
Implementation Method 2
Key factor for cutting is transforming absorbed laser energy into heat, to melt material
Implementation Method 3
high laser energy of a small spot size oscillates periodically and is superimposed with the feed rate. Thus, energy is distributed around the generated cut kerf and thereby acting as an artificial bigger spot
Implementation Method 4
Key factor for cutting is transforming absorbed laser energy into heat, to melt material
Implementation Method 5
transforming absorbed laser energy into heat, to melt material
Data Source
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AI summary
In one aspect the invention relates to a control unit (100) for providing control instructions (ci) for controlling a laser cutting machine (L) by determining transition phases for transforming different dynamic laser beam shapes for the laser cutting machine (L), preferably comprising a dynamic laser beam shaping module (DBSM) for dynamically varying the shape of the laser beam. The control unit (100) comprises: A cutting plan interface (101) for receiving a cutting plan to be processed for cutting out parts of a workpiece, wherein each part is defined by a cutting contour consisting of cutting segments, which are ordered in a queue; An allocation tool (102), which is configured to allocate a specific dynamic laser beam shape from a set of dynamic laser beam shapes to each cutting segment in the queue of cutting segments according to predefined assessment criteria; A transition tool (104) for determining transition phases between each two consecutive specific dynamic laser beam shapes, wherein a first specific dynamic laser beam shape of the two consecutive specific dynamic laser beam shapes is transformed into a second specific dynamic laser beam shape of the two consecutive specific dynamic laser beam shapes within a transition time (t); A processor (P), which is configured for accessing the allocation tool (102) iteratively for determining a specific dynamic laser beam shape for each cutting segment of the queue of cutting segments and wherein the processor (P) is further configured for accessing the transition tool (104) for determining all transition phases between each two consecutive specific dynamic laser beam shapes and wherein the processor (P) is configured for providing control instructions (ci) for controlling the laser cutting machine (L) for executing the received cutting plan by applying: 1. the specific dynamic laser beam shape, determined by the allocation tool (102), and 2. the transition phases between each two consecutive specific dynamic laser beam shapes, being determined by the transition tool (104).