Laser Cutting Disruption Detection via Intensity Profile Analysis
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Solution Overview
Problem
Existing machining processes, particularly laser cutting, face challenges in reliably distinguishing between real and pseudo-incomplete cutting actions due to geometric similarities caused by supporting bars or double metal sheets, leading to inaccurate identification of disruptions.
Innovation Solution
The method involves capturing and evaluating images of the interaction region in real-time using an imaging sensor system, analyzing the intensity profile to detect local intensity drops, and combining this with geometric features to differentiate between real and pseudo-incomplete cutting actions, thereby accurately identifying disruptions during the machining process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If geometric features of the interaction region are used to identify incomplete cutting actions, then disruption detection is enabled, but pseudo-defects occur due to geometric similarities caused by supporting bars or double metal sheets
Solution Approach 1:
The patent transitions from analyzing only geometric features (2D spatial characteristics) to incorporating intensity profile analysis (adding the intensity dimension). By evaluating both the geometric shape of the interaction region and the intensity distribution within it, the system can distinguish between real incomplete cutting actions and pseudo-defects caused by supporting bars, as they exhibit different intensity characteristics despite similar geometries.
2Reliability
If the observation direction is oriented at a polar angle greater than 5° in relation to the optical axis, then incomplete cutting actions can be detected, but pseudo-defects occur due to overlapping effects from other process parameters
Solution Approach 1:
The patent segments the analysis into multiple independent evaluation criteria: geometric features of the interaction region, intensity profile characteristics, and their combination. By dividing the detection task into these separate analytical dimensions, the system can weigh different features and identify which combination most reliably indicates a real incomplete cutting action versus a pseudo-defect, reducing false positives from overlapping effects.
3Measurement precision
If multiple characteristics are analyzed to improve disruption identification, then accuracy increases, but device complexity and evaluation time increase
Solution Approach 1:
The patent employs a single imaging device that serves multiple functions: capturing geometric information, measuring intensity distribution, and providing temporal resolution for real-time monitoring. This multi-functional approach allows comprehensive analysis of multiple characteristics without proportionally increasing device complexity, as one versatile imaging system replaces what would otherwise require multiple specialized sensors.
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 reliable identification of incomplete cutting actions and position-dependent disruptions, allowing for precise adjustments in the machining process to prevent errors and optimize cutting performance.
Implementation Method 1
recording an image of a region on the workpiece to be monitored, said region to be monitored comprising an interaction region of the machining tool with the workpiece, and evaluating the image of the region to be monitored
Data Source
AI summary
A method for identifying disruptions during a machining process, more particularly during a cutting process, includes: machining, more particularly cutting, a workpiece while moving a machining tool, in particular a laser machining head, and the workpiece relative to one another, recording an image of a region on the workpiece to be monitored, the region to be monitored being an interaction region of the machining tool with the workpiece, and evaluating the image of the region to be monitored. For the purpose of identifying at least one disruption of the machining process, the presence or the lack of a local intensity drop in an intensity profile within the interaction region is detected, during the evaluation of the image, in an advancement direction of the machining process. There is also described an associated machining apparatus.