In-Line Laser Cutter Calibration on Moving Webs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Laser processing machines require periodic calibration to maintain precision due to environmental changes, and existing calibration methods are offline, disrupting production and requiring operator assistance.
Innovation Solution
A method for characterizing and calibrating laser processing machines involves moving a medium along the machine's working area, processing marks with the laser synchronized with the medium's motion, and using cameras to record the marks, allowing for in-line characterization and calibration without stopping production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If offline calibration method is used, then measurement precision is improved, but productivity deteriorates due to production interruption
Solution Approach 1:
The patent implements continuous calibration by processing calibration marks on the medium while it moves through the working area, eliminating the need to stop production for calibration. The laser system continuously processes marks and the camera continuously records them, maintaining uninterrupted workflow while achieving calibration objectives.
Solution Approach 2:
The patent introduces a camera as an intermediary measurement device that captures calibration mark positions directly within the working area. This intermediary system enables real-time position detection without requiring external offline measurement equipment, facilitating continuous calibration during production.
2Measurement precision
If offline calibration method is used, then measurement precision is improved, but device complexity increases due to additional equipment
Solution Approach 1:
The patent makes the existing laser system and camera serve multiple functions: the laser processes both production marks and calibration marks, while the camera records both production output and calibration mark positions. This multi-functionality eliminates the need for separate dedicated calibration equipment, reducing overall system complexity.
Solution Approach 2:
The system performs self-calibration by using its own laser and camera resources to measure and correct its positioning accuracy. The calibration process is integrated into the normal production workflow, with the system calibrating itself without requiring external measurement devices or additional specialized equipment.
3Measurement precision
If offline calibration method is used, then measurement precision is improved, but ease of operation deteriorates due to operator assistance requirement
Solution Approach 1:
The system automatically performs calibration without operator intervention. The laser processes calibration marks, the camera records positions, and the control unit computes corrections autonomously. This automation eliminates the need for operator assistance in positioning measurement equipment or manually operating calibration devices.
Solution Approach 2:
The system implements automatic feedback control where the camera measures actual mark positions, the control unit compares them with nominal positions, computes correction values, and applies them to the laser positioning. This closed-loop feedback system automatically maintains calibration without requiring manual measurement and adjustment by operators.
4Manufacturing precision
If marks are spread across entire working area, then manufacturing precision is improved, but loss of substance increases due to medium waste
Solution Approach 1:
The patent concentrates calibration marks in a localized region rather than spreading them across the entire working area. By placing multiple calibration marks within a confined space, the system achieves sufficient calibration accuracy while minimizing the amount of medium consumed, thus reducing waste.
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 method enables precise characterization and calibration of laser processing machines, reducing waste, allowing for in-line processing, and jointly compensating for motion defects and laser positioning errors, thereby improving production efficiency and accuracy.
Implementation Method 1
A laser processing machine directs a laser beam toward the sheet of material to be processed, with the appropriate focus, power and pulse duration, to either mark, crease or cut the sheet
Implementation Method 2
records each individual mark using a camera
Data Source
AI summary
The present invention discloses a method to calibrate a laser cutting machine without stopping the production. The method is adapted to laser cutting machine which use a conveyor belt to convey the sheets while cutting them with the laser. The method allows to place calibration marks at locations on the sheet that are convenient according to the production job, thereby minimising the waste of material.