Laser Cutting Nesting with Geometry-Based Part Spacing
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Solution Overview
Problem
Existing nesting methods for laser cutting result in inefficient use of workpiece sheets due to uniform workpiece spacings, leading to excessive waste and a high risk of workpiece parts tilting and colliding with the cutting head.
Innovation Solution
A computer-implemented nesting method that determines individual workpiece spacings based on geometry characteristics to optimize material use and reduce process risks, such as tilting and collision, by using algorithms, artificial intelligence, or look-up tables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If uniform minimum workpiece part distance is used between adjacent workpiece parts, then collision risk between tilted workpiece parts and laser cutting head is reduced, but workpiece sheet utilization efficiency deteriorates and waste increases
Solution Approach 1:
The patent applies local quality by determining individual workpiece spacings based on the specific geometry characteristics of each workpiece part and its adjacent parts. Instead of using a uniform spacing for all parts, the system calculates risk-specific spacings tailored to local geometric conditions, such as parts with protrusions or recesses that may tilt during cutting. This allows minimal spacing where geometry permits and larger spacing only where collision risk requires it, thereby optimizing workpiece sheet utilization while maintaining collision safety.
2Reliability
If conservative uniform spacing of 15 mm is chosen across all workpiece parts, then collision risk is minimized, but material waste increases and nesting efficiency deteriorates
Solution Approach 1:
The patent implements parameter changes by dynamically adjusting the workpiece spacing parameter based on geometry characteristics of individual parts. The system calculates a risk value for each workpiece part considering factors such as part geometry, support structure, and laser cutting parameters, then determines an optimal spacing specific to each part. This replaces the static 15 mm uniform spacing with variable spacings that range from minimal to larger values only where geometric analysis indicates collision risk, thereby reducing material waste while maintaining safety.
3Productivity
If individual workpiece spacings are determined based on geometry characteristics, then workpiece sheet utilization efficiency is improved and waste is reduced, but calculation complexity and processing time increase
Solution Approach 1:
The patent applies preliminary action by performing geometry characteristic analysis and risk calculation for each workpiece part before the nesting arrangement is finalized. The system pre-calculates risk values based on part geometry, support structure, and cutting parameters, storing these results for use during nesting optimization. This preliminary assessment enables the nesting algorithm to quickly determine appropriate spacings without complex real-time calculations during the nesting process itself, thereby reducing overall processing time while achieving optimal material utilization.
Data Source
AI summary
A nesting method for generating a nesting plan by nesting workpiece parts with different two-dimensional workpiece part geometries on a workpiece sheet with a two-dimensional workpiece sheet geometry, wherein the nesting plan is configured to be used for a laser cutting method for cutting the workpiece parts nested according to the nesting plan out of the workpiece sheet placed on a workpiece support. The nesting method includes reading in geometry data of the workpiece parts, ascertaining individual geometry characteristics of at least some of the workpiece parts from their geometry data, determining individual workpiece spacings between adjacent workpiece parts on the workpiece sheet based on their individual geometry characteristics, and nesting the workpiece parts with their individual workpiece spacings on the workpiece sheet.