Laser Cladding Motion Control for Overlap and Head Height Compensation
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Solution Overview
Problem
In single-layer laser cladding of shaft-like workpieces, the traditional motion control systems fail to accurately control the motion relationship between the spindle and feed shaft, leading to a contradiction between the workpiece clamping allowance and motion planning, affecting processing quality and efficiency.
Innovation Solution
A method and system that dynamically adjust motion planning by considering the overlapping rate and workpiece clamping allowance, using S-curve and triangular acceleration planning algorithms to synchronize the spindle and feed shaft velocities, and a laser head height adjustment mechanism to compensate for workpiece deflection and deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional motion control systems are used for spindle and feed shaft, then the system structure is simple, but the motion relationship cannot be accurately controlled affecting overlapping rate precision
Solution Approach 1:
The patent implements a feedback mechanism where the actual positions and velocities of the spindle and feed shaft are continuously monitored and compared with the planned motion trajectory. The control system dynamically adjusts the motion parameters based on this feedback to ensure the overlapping rate remains within the specified tolerance range, thereby achieving precise control without excessive system complexity.
Solution Approach 2:
The patent employs dynamic motion planning that adapts the velocity and acceleration profiles of the spindle and feed shaft in real-time. By making the motion parameters dynamic rather than fixed, the system can accommodate variations in workpiece geometry and clamping conditions while maintaining accurate overlapping rate control.
2Adaptability or versatility
If clamping allowance is increased to accommodate motion planning variations, then motion planning flexibility is improved, but workpiece processing precision deteriorates
Solution Approach 1:
The patent dynamically adjusts motion parameters such as velocity, acceleration, and timing of the spindle and feed shaft based on real-time position feedback and pre-calculated optimal trajectories. By optimizing these parameters within the clamping allowance constraints, the system achieves both motion planning adaptability and cladding layer precision without requiring excessive clamping allowance.
3Productivity
If high velocity laser cladding is implemented, then processing efficiency is improved, but motion synchronization between spindle and feed shaft becomes more difficult affecting quality
Solution Approach 1:
The patent performs preliminary calculation of optimal motion trajectories and parameters for the spindle and feed shaft before the actual laser cladding process. By pre-planning the synchronized motion paths and velocities, the system ensures that even at high processing speeds, the coordination between components remains precise, maintaining cladding quality while achieving high productivity.
Data Source
AI summary
Provided are a method and a system for controlling the overlapping in the single-layer laser cladding of a shaft-like workpiece, and a method, a device and a system for dynamically adjusting a height of the laser head of a laser cladding machine. In the method for controlling the overlapping in the laser cladding of the shaft-like workpiece, the motions of the spindle and the feed shaft are planned based on an S-curve acceleration and deceleration method. The motion planning is dynamically adjusted by comprehensively considering the overlapping rate and the clamping allowance of the workpiece in a feed direction.