Curvilinear Cross-Jet Nozzle for Laser Head Debris Deflection
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Solution Overview
Problem
The existing laser processing head systems require frequent replacement of protective cover slides and high compressed air consumption to deflect debris, leading to increased operating costs and downtime.
Innovation Solution
A cross-jet module with a curvilinear nozzle design that reduces gas consumption by optimizing the deflection angle and flow pattern of the cross-jet, minimizing the amount of compressed air needed to effectively protect the cover slide from debris.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If a cross-jet of compressed air is used to deflect debris away from the cover slide, then the service life of the cover slide is extended, but the operating costs increase due to high compressed air consumption
Solution Approach 1:
The patent applies a curvilinear nozzle design with a curved outlet geometry that optimizes the flow pattern of the cross-jet. The curved outlet creates a more effective deflection angle for debris while reducing the required gas flow rate, thereby extending cover slide service life without proportionally increasing compressed air consumption
Solution Approach 2:
The patent modifies the nozzle geometry parameters, specifically the outlet curvature radius and angle, to optimize the cross-jet flow characteristics. By changing these geometric parameters, the system achieves better debris deflection efficiency with reduced gas consumption, resolving the contradiction between protective effectiveness and operating costs
2Reliability
If a sufficient amount of compressed air is supplied to protect the cover slide, then debris deflection performance is improved, but the operating costs and production line downtime increase
Solution Approach 1:
The curvilinear nozzle design creates an optimized flow distribution that maintains reliable debris deflection performance while reducing the total volume of compressed air required. This efficiency gain reduces operating costs and minimizes production interruptions for maintenance
Solution Approach 2:
By optimizing the nozzle geometric parameters, the system achieves superior debris deflection reliability with lower gas consumption, thereby improving overall production efficiency without compromising protective function
3Device complexity
If a linear geometry nozzle is used for the cross-jet module, then the structure is simple, but the gas consumption is high and deflection performance is suboptimal
Solution Approach 1:
The patent transitions from a linear nozzle geometry to a curvilinear design with a curved outlet. This geometric modification significantly improves gas flow efficiency and debris deflection performance while maintaining manufacturing feasibility, thereby reducing energy loss without excessive structural complexity
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 curvilinear nozzle design reduces gas consumption by approximately 40% while maintaining or improving deflection performance, thereby extending the service life of the cover slide and lowering operational costs.
Implementation Method 1
A cross-jet module with a curvilinear nozzle design that reduces gas consumption by optimizing the deflection angle and flow pattern of the cross-jet
Data Source
AI summary
A laser material processing head, such as a remote welding head, has an output with a protective optic configured to pass an emitted laser to a working area. The protective optic, such as a cover slide of the output, protects other optics inside the head and is a replaceable, spare part. To prevent at least some debris expelled from the working area from reaching the protective optic, a nozzle is mounted to the head adjacent to the protective optic. The nozzle has an inlet and an outlet for the gas. The outlet has a curvilinear profile configured to fan a cross-jet of the gas in the plane between the protective optic and the working area. The profile of the nozzle reduces the amount of gas needed to divert the debris from the protective optic.