Laser Cutting Parameter Optimization With Bayesian Closed-Loop Modeling

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Solution Overview

Problem

Current methods for calculating process parameters in laser cutting are time-consuming and costly, especially when dealing with slightly different material compositions or thicknesses, as they require extensive training and testing, making them inefficient for real-time optimization and prone to quality deficiencies.

Innovation Solution

A method using Bayesian optimization with a closed-loop control system that dynamically generates a statistical model based on a limited set of test cuts, allowing for the calculation of material-specific and machine-specific process parameters without the need for extensive neural network training, focusing on optimizing key criteria like quality and performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If neural network training is used to determine optimized process parameters, then the reliability of process results is improved, but the time consumption and costs increase significantly

Engineering Contradiction:
Improvereliability of process resultsVSAvoidtime consumption for training and testing
Core Design Contradiction:
ReliabilityVSLoss of time

Solution Approach 1:

The patent applies preliminary action by pre-training the neural network model once with comprehensive training data to establish a robust prediction system. This initial training phase creates a reusable model that can quickly determine optimized process parameters without requiring repeated extensive training when new materials or machines are introduced, thus resolving the contradiction between reliability and time consumption.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent uses copying by creating a virtual model (neural network) that replicates the complex relationships between process parameters and outcomes. This virtual model can be trained once and then copied/reused multiple times for different material and machine combinations, eliminating the need for repeated physical experiments and extensive training phases, thereby reducing time and costs while maintaining reliability.

Inventive Principle:
Principle #26Copying

2Manufacturing precision

If extensive training and testing are performed for each new material or machine setting, then the accuracy of process parameters is improved, but the productivity decreases

Engineering Contradiction:
Improveaccuracy of process parametersVSAvoidproductivity for real-time optimization
Core Design Contradiction:
Manufacturing precisionVSProductivity

Solution Approach 1:

The system performs preliminary training of the neural network model in advance, creating a pre-trained model that can quickly adapt to new materials or machines. This preliminary action ensures high accuracy is achieved through comprehensive initial training, while the pre-trained state enables rapid deployment without extensive retraining, thus maintaining productivity for real-time optimization.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent applies parameter changes by allowing the neural network model to efficiently adjust its internal parameters (weights and biases) when adapting to new materials or machine settings. This enables the system to maintain high accuracy through proper parameter tuning while requiring minimal time for adaptation, thereby resolving the contradiction between manufacturing precision and productivity.

Inventive Principle:
Principle #35Parameter changes

3Loss of time

If stored expert knowledge is used to calculate process parameters, then the processing time is reduced, but the adaptability to new materials and machines deteriorates

Engineering Contradiction:
Improveprocessing time for parameter calculationVSAvoidadaptability to new materials and machines
Core Design Contradiction:
Loss of timeVSAdaptability or versatility

Solution Approach 1:

The patent replaces the mechanical system of stored expert knowledge (static, rule-based approaches) with an intelligent system (neural network model). This substitution maintains the speed advantage of pre-computed solutions while adding the adaptability of machine learning, as the neural network can learn and adapt to new materials and machines without requiring manual reprogramming of expert rules, thus resolving the contradiction between processing time and adaptability.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP4168209B1Computer implemented method of and optimisation tool for refinement of laser cutting process parameters by means of an optimization tool, with corresponding computer program
Publication Date: 2024.06.05 BYSTRONIC LASER AG
  • EP4168209B1 patent drawingFigure 1
  • EP4168209B1 patent drawingFigure 2
  • EP4168209B1 patent drawingFigure 3

AI summary

In one aspect the invention relates to a method of calculating process parameters, which are optimized for processing a workpiece with specific material properties by means of a laser machine, comprising the method steps of: Determining (S10) material properties for which the process parameters should be optimized; Determining (S20) preconfigured initial process parameters; Executing a re-optimization algorithm (S30) until a target objective function is minimized or maximized for calculating optimized material-specific process parameters by accessing a storage with a statistical model, wherein the statistical model is based on Bayesian optimization using Gaussian Processes as priors.