Laser-Cut Part Removal Using Sensor-Based Complication Classification
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Solution Overview
Problem
Existing cutting systems face challenges in removing parts from a workpiece due to complications such as incomplete cutting, adherence to the workpiece support, tilted orientation, position deviations, and contamination, which hinder efficient sorting and automation.
Innovation Solution
A laser cutting apparatus equipped with a sensor device, removal device, and control unit that utilizes optical and depth sensors, machine learning algorithms, and a gripping arm to identify, classify, and handle parts with complications, adjusting cutting and removal strategies to overcome these issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If standard removal devices are used to remove cut parts, then parts without removal complications can be removed efficiently, but parts with removal complications (incomplete cutting, adherence, tilted orientation, position deviations, contamination) cannot be removed
Solution Approach 1:
The removal device is designed with dynamically adjustable gripping elements that can adapt their position, angle, and gripping force based on real-time sensor feedback about the part's orientation, position, and contamination state. This allows the same device to handle both standard parts efficiently and parts with removal complications effectively.
Solution Approach 2:
Sensor devices detect the actual state of cut parts (orientation, position, contamination, adherence) and provide feedback to the control unit, which then adjusts the removal device's parameters accordingly. This closed-loop control enables the system to adapt to parts with removal complications while maintaining efficiency for standard parts.
2Ease of operation
If the workpiece support structure is simplified for easier part removal, then removal becomes more efficient, but parts may fall between rest elements and become unreachable
Solution Approach 1:
The workpiece support structure serves multiple functions: it provides rest elements for stable part placement during cutting, maintains appropriate gaps to prevent part entrapment, and works in conjunction with sensor devices to detect and locate parts that may be in difficult-to-reach positions. The support structure is designed with optimized spacing that balances ease of removal with part accessibility.
3Manufacturing precision
If cutting precision is increased to reduce removal complications, then fewer parts have removal issues, but cutting time increases and productivity decreases
Solution Approach 1:
The system performs preliminary detection of cut parts using sensor devices immediately after cutting. This early detection identifies parts with potential removal complications (incomplete cuts, adherence, tilted orientation) before the removal process begins, allowing for corrective actions or adaptive removal strategies to be applied without significantly increasing cutting time.
Solution Approach 2:
The system dynamically adjusts cutting parameters such as laser power, cutting speed, and gas pressure based on real-time feedback from sensor devices. This allows optimization of the cutting process to achieve sufficient precision while maintaining high productivity, adapting parameters to prevent removal complications rather than relying on uniformly high precision settings.
4Adaptability or versatility
If sensor devices and classification systems are added to identify and handle parts with removal complications, then parts with complications can be managed, but device complexity increases
Solution Approach 1:
The system replaces complex mechanical inspection and classification mechanisms with sensor devices (optical, capacitive, inductive) and automated image processing algorithms. These sensors detect part characteristics and the control unit classifies parts with removal complications through software-based analysis, eliminating the need for additional mechanical classification hardware while achieving high adaptability.
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
Enables the efficient removal and sorting of parts with removal complications, optimizing cutting plans and automation, and providing real-time monitoring for improved production efficiency.
Implementation Method 1
sensor device (112) for detecting the cut parts (12) in the remainder of the workpiece (14)
Implementation Method 2
parts (12) are cut from a workpiece (10) according to a cutting plan
Implementation Method 3
laser cutting apparatus (100) equipped with a sensor device (112)
Data Source
Figure 1a
Figure 1b~1c
Figure 2a~5a
AI summary
Disclosed are a method and an apparatus for cutting parts from a workpiece according to a cutting plan and for removing the cut parts from a remainder of the workpiece. The method comprises the steps: detecting the cut parts in the remainder of the workpiece by means of a sensor device, providing sensor data on the detected cut parts and comparing the sensor data with the cutting plan (SA); identifying cut parts with at least one removal complication on the basis of the sensor data (SB); classifying the identified parts according to a predetermined removal complication classification, with each identified part being assigned at least one complication class (SC); removing cut parts which are free of a removal complication by means of a removal device (SD); and handling the classified parts with at least one removal complication according to at least one handling step assigned to the complication class (SE).