Laser Cut Quality Scanning for In-Process Parameter Adjustment
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Solution Overview
Problem
Current laser cutting processes face challenges in monitoring cutting quality due to the physical properties of online monitoring, which limits the ability to measure quality features directly from process emissions, especially for laser cutting where cut surfaces are perpendicular to the direction of observation, leading to uncertain online assessment of cutting quality.
Innovation Solution
An offline method is introduced where the cutting process is interrupted after a partial processing step, allowing for high-speed scanning of the cut section to directly measure quality features like slag residue, cutting edge roughness, and kerf width without part removal, enabling immediate post-processing quality control and adjustment of cutting parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If online process monitoring is used to monitor cutting quality in real time, then process security is improved, but measurement precision deteriorates because cut surfaces are perpendicular to the direction of observation and quality features cannot be measured directly
Solution Approach 1:
The patent applies preliminary action by interrupting the cutting process before completion to perform offline quality detection. The detector system scans the cut surface while the workpiece is still in position, measuring quality features directly before the cut is finalized. This allows precise measurement of cut edge quality, slag residue, and kerf width without the limitations of online monitoring where the cut surface is perpendicular to observation.
2Measurement precision
If offline detection is performed by interrupting the cutting process, then measurement precision of quality features is improved, but productivity deteriorates due to process interruption and additional scanning time
Solution Approach 1:
The patent maintains continuity of useful action by performing the detection function during the cutting process itself. The detector system operates concurrently with the cutting head, scanning the cut surface as it is being created. The system continuously monitors quality features without requiring complete process interruption, thereby maintaining high productivity while achieving precise offline-quality measurement.
Solution Approach 2:
The system dynamically adjusts the detection frequency and scanning parameters based on process conditions. The control unit determines when offline detection should be performed during the cutting process, balancing measurement needs with productivity requirements. This dynamic approach allows the system to perform detailed quality analysis only when necessary, maintaining high overall cutting speed while ensuring quality control.
3Productivity
If online monitoring uses detector signals that correlate with cutting quality, then productivity is maintained, but measurement precision deteriorates due to uncertainty in correlation between detector signals and actual quality features
Solution Approach 1:
The patent introduces an intermediary offline detection system that directly measures quality features rather than relying on indirect detector signal correlations. The detector system scans the cut surface to directly observe slag residue, cut edge roughness, and kerf width, providing accurate quality assessment without the uncertainty of signal correlation. This intermediary measurement system bridges the gap between maintaining productivity and achieving precise quality measurement.
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 allows for precise and rapid determination of cutting quality features, reducing unproductive times and increasing process security by enabling early intervention in poor cutting quality, suitable for various workpieces and sheet thicknesses, including those with unstable cutting processes.
Implementation Method 1
at least one detector system for recording radiation reflected from the scan area, or emitted, in particular, thermal radiation
Data Source
AI summary
A method and a device for monitoring laser cutting processes in the high-power range above 1 kW mean output envisage automatic quality control after interruption and/or completion of a cutting process carried out with predetermined cutting parameters. According to the disclosure the cutting process is interrupted after a first partial processing step, whereupon a partial section (K1 . . . KX) of the processing path is scanned. This preferably takes place at a higher speed than that for the first partial processing procedure and preferably close to or on the same processing path. On the basis of the scan result at least one quality feature of the processing result is automatically determined and compared with predefined quality specifications. Depending on the result of the comparison a fault message can then be issued, the processing interrupted, reworking of a defect point carried out, at least one cutting parameter adjusted, and the cutting process continued with the changed set of cutting parameters.