Laser Cutting Contour Calibration Using Optical Deviation Mapping
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Solution Overview
Problem
Laser cutting machines face challenges in achieving both high precision and productivity due to contour deviations caused by inertia, resilience, and vibrations of machine components, which are not accurately measured by existing encoder systems, leading to reduced quality and increased production time.
Innovation Solution
A method involving a computer-implemented process that applies a reference texture, such as an engraving, to the workpiece, captures images with an optical device, and calculates displacement vectors to determine contour deviations, allowing for precise calibration and compensation of control instructions to correct these deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the cutting speed is increased to improve productivity, then the productivity increases, but the contour precision deteriorates due to overshooting from inertia and resilience
Solution Approach 1:
The patent applies preliminary action by pre-calculating and storing compensation values for contour deviations at different positions and speeds before actual cutting. The system determines the actual cutting contour by comparing target contour with pre-measured compensation data, allowing high-speed cutting while maintaining precision through pre-computed corrections.
Solution Approach 2:
The patent implements feedback by using optical measurement systems to detect actual cutting contours and comparing them with target contours. The system continuously monitors position deviations and uses encoder feedback to determine actual positions, creating a closed-loop control that corrects for inertia and resilience effects during cutting.
2Manufacturing precision
If blanket restrictions are applied to machine dynamics to ensure contour accuracy, then the manufacturing precision improves, but the productivity decreases
Solution Approach 1:
The patent applies local quality by determining contour deviations specifically at corner positions and high-dynamic areas where precision problems occur, rather than applying blanket restrictions to the entire cutting path. The system measures and compensates for deviations locally at critical positions, allowing high-speed cutting in low-risk areas while maintaining precision at corners.
Solution Approach 2:
The patent changes parameters by storing multiple compensation values for different positions, speeds, and acceleration levels. The system selects appropriate compensation parameters based on actual cutting conditions, allowing dynamic adjustment of cutting parameters to maintain precision without blanket speed restrictions.
3Manufacturing precision
If optical measurement systems are used to measure the actual cutting contour, then the manufacturing precision improves, but the device complexity increases
Solution Approach 1:
The patent applies copying by creating a digital model of the actual cutting contour through optical measurement and comparing it with the target contour model. The system uses camera-based optical systems to capture images of the workpiece and reconstruct the actual cutting path, providing a simplified digital copy for analysis and compensation.
4Device complexity
If internal encoder measurement systems are used to measure position, then the device complexity is reduced, but the measurement precision deteriorates because they cannot account for inertia and resilience
Solution Approach 1:
The patent uses an intermediary approach by combining simple encoder measurements with optical measurement systems. The encoders provide basic position feedback while optical systems serve as intermediaries to measure actual cutting contours and detect deviations caused by inertia and resilience. The combined data provides accurate position and contour information without the complexity of purely optical systems.
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 approach enables precise calibration of laser cutting machines without waste, improving quality and productivity by reducing contour errors and optimizing control values for machine components, thus enhancing the accuracy of cuts.
Implementation Method 1
spatially resolved detection of a surface area of the heated workpiece by the optical detector
Data Source
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AI summary
In one aspect, the present invention relates to the calculation of contour deviations (ka) for controlling a laser cutting machine (L) with control instructions (sa). The contour deviations (ka) are calculated from a displacement vector (vv), which is determined from an image comparison between an image captured by a camera (K) and a virtual reconstruction image (v). The virtual reconstruction image (v) is determined on the basis of a reference texture (RT) applied to the workpiece (W) and control values (sw).