Laser Cutting Gap Sensor Calibration and Reflected Light Measurement
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Solution Overview
Problem
Conventional laser cutting apparatuses face reduced operating rates due to the time-consuming processes of gap sensor calibration and reflected light profile measurement, which are required each time a processing object is replaced, leading to frequent interruptions and reduced productivity.
Innovation Solution
A laser cutting apparatus and correlation table generation method that simultaneously perform gap sensor calibration and reflected light profile measurement by using a correlation table generation unit to store and correlate output values, reflected light intensity, and positional information, allowing for synchronized and stepwise movement of the cutting head while controlling the laser beam output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If gap sensor calibration and reflected light profile measurement are performed separately as conventional procedures, then measurement precision is improved, but productivity deteriorates due to increased processing time
Solution Approach 1:
The patent combines gap sensor calibration and reflected light profile measurement into a single integrated process. The correlation table generation unit simultaneously performs both functions by correlating gap sensor output values with reflected light intensity values at the same gap positions, eliminating the need for separate calibration and measurement operations.
Solution Approach 2:
The patent performs gap sensor calibration in advance by storing correlation data between gap sensor output values and actual gap distances in a correlation table. This preliminary calibration allows the system to use the gap sensor for real-time gap control during laser processing without requiring repeated calibration operations, thereby improving productivity.
2Measurement precision
If gap sensor calibration is performed each time the processing object is replaced, then measurement precision is maintained, but loss of time increases
Solution Approach 1:
The system performs gap sensor calibration in advance and stores the correlation data in a correlation table. When the processing object is replaced, the pre-calibrated correlation table is used directly, eliminating the need for time-consuming recalibration operations while maintaining measurement precision.
Solution Approach 2:
The patent creates a correlation table that copies the relationship between gap sensor output values and actual gap distances from calibration measurements. This copied correlation data can be reused for multiple processing objects, avoiding repeated calibration time while maintaining accuracy through the stored correlation relationship.
3Reliability
If reflected light intensity is monitored to prevent laser oscillator damage, then reliability is improved, but productivity deteriorates due to frequent processing interruptions
Solution Approach 1:
The system performs reflected light profile measurement in advance and stores the data in the correlation table. By having the reflected light characteristics预先 measured and stored, the system can predict when reflected light intensity may exceed safe levels during processing, allowing for preventive measures to be taken before actual damage occurs, thereby maintaining both reliability and productivity.
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 efficient simultaneous calibration and measurement, improving the operating rate of the laser cutting apparatus by reducing the time required for these processes and minimizing interruptions during processing.
Implementation Method 1
a gap sensor configured to detect a distance between the cutting head and the processing object
Implementation Method 2
a detection unit configured to detect intensity of a laser beam that is reflected from the processing object and returned to the laser oscillator
Data Source
AI summary
A laser cutting apparatus includes a laser oscillator; an output control unit for a laser beam; a cutting head configured to emit the laser beam; a gap sensor; an axial mechanism configured to activate the cutting head; an axial control unit; a detection unit configured to detect reflected light intensity; a storage unit configured to store an output value of the laser beam, reflected light intensity, a detection value of the gap sensor, and positional information of the axial mechanism; and a correlation table generation unit configured to output an instruction to operate the axial mechanism and the laser oscillator, and generates a correlation table configured to obtain a correlation between the output value of the laser beam and the reflected light intensity, a correlation between the positional information and the reflected light intensity, and a correlation between the detection value and the positional information.