Laser Cutting Head Scanning for Real-Time Miscut Detection
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Solution Overview
Problem
Laser cutting machines often result in incomplete cuts (miscuts) due to the inability to accurately determine and correct cutting errors in real-time, leading to inefficient re-cutting processes and suboptimal cutting results.
Innovation Solution
A method and system that uses a high-power laser cutting beam to cut a workpiece, followed by a low-power laser scanning beam to identify miscuts during the return travel of the machining head, allowing for real-time detection and evaluation of cutting parameters to adjust settings and prevent miscuts, thereby improving cutting accuracy and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a high-power laser cutting beam is used to cut the workpiece, then cutting speed and productivity are improved, but the risk of incomplete cuts (miscuts) increases due to inability to detect errors in real-time
Solution Approach 1:
The patent implements a feedback mechanism by using a laser scanning beam to detect the cutting line after the high-power cutting beam passes through. The scanning beam verifies whether the cut is complete and provides feedback information to the control device, which can then trigger re-cutting if a miscut is detected. This closed-loop feedback system resolves the contradiction by enabling real-time quality verification without compromising the high-speed cutting capability.
Solution Approach 2:
The patent applies preliminary action by performing the scanning detection immediately after the cutting operation while the machining head is still in position. The scanning beam checks the cutting line before the workpiece is moved or the machining head repositions, allowing for immediate detection and correction of miscuts. This preliminary verification ensures cutting accuracy without requiring separate inspection steps that would reduce productivity.
2Manufacturing precision
If miscuts are detected and corrected by re-cutting the workpiece, then cutting accuracy is improved, but production time is increased due to repeated cutting operations
Solution Approach 1:
The feedback mechanism immediately identifies miscuts during or right after the cutting process, allowing the control device to trigger targeted re-cutting only at the specific locations where miscuts occurred. This prevents the need for complete re-cutting of the entire workpiece, thereby maintaining high cutting accuracy while minimizing the time loss associated with corrections.
Solution Approach 2:
The patent applies local quality by performing re-cutting operations only at the specific locations where miscuts were detected, rather than re-cutting the entire workpiece. The scanning beam identifies precise problem areas, and the control device directs the cutting beam to those specific locations, thereby improving cut accuracy while significantly reducing the time penalty compared to complete re-cutting.
3Measurement precision
If a distance sensor is moved over the workpiece to check for complete breakthrough, then miscut detection accuracy is improved, but device complexity and measurement time are increased
Solution Approach 1:
The patent applies universality by using the laser scanning beam to serve multiple functions: it acts as both the cutting tool (when high power is applied) and the measurement/detection device (when scanning the cutting line). This multi-functional approach eliminates the need for separate distance sensors and complex sensor systems, achieving high miscut detection accuracy while reducing device complexity. The same optical system performs both cutting and verification tasks.
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 real-time identification and correction of miscuts, reducing the risk of incomplete cuts and improving the overall cutting performance by optimizing parameter settings and minimizing unnecessary re-cutting, thus enhancing the quality and efficiency of the laser cutting process.
Implementation Method 1
cutting a workpiece using a laser cutting beam having a high power along a cutting line
Implementation Method 2
Laser radiation from a laser cutting machine at high power, usually in the range of multiple kilowatts, is used in cutting workpieces
Implementation Method 3
scanning the cutting line on the workpiece using a laser scanning beam having a low power
Implementation Method 4
scanning the cutting line on the workpiece using a laser scanning beam having a low power or using an illumination beam
Data Source
AI summary
A laser cutting method using a laser cutting machine includes a) cutting a workpiece using a laser cutting beam having a high power along a cutting line, b) scanning the cutting line on the workpiece using a laser scanning beam having a low power or using an illumination beam, and recording scanning data, c) changing at least one parameter of a plurality of parameters the laser cutting machine, repeating steps a) and b), and evaluating the scanning data with respect to the plurality of parameters of the laser cutting machine in a control device. The scanning of the cutting line on the workpiece using the laser scanning beam of the low power is carried out during a return travel of a laser machining head.