Laser Cutting Parameter Control for Irregular Surface Tracking
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Solution Overview
Problem
Laser cutting of complex shapes with irregular surfaces is challenging due to the need for frequent changes in machining conditions, leading to deviations in the laser machining head's track and increased processing time, especially when dealing with materials of varying thicknesses and surface irregularities.
Innovation Solution
A laser cutting device and method that utilize a control unit to select machining condition tables based on material and thickness, adjusting cutting speed and laser power output to maintain given finishing conditions, ensuring stable and efficient cutting by overlapping the effective and usable ranges of cutting speed and power output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the laser machining head is moved at high speed on a flat surface to reduce processing time, then productivity is improved, but when the work has irregularities on its surface requiring frequent changes in machining conditions, the tracking accuracy deteriorates and manufacturing precision worsens
Solution Approach 1:
The patent pre-calculates and stores optimal machining conditions (laser power, cutting speed, focus position) in a machining condition table before actual cutting. The controller automatically selects appropriate conditions based on the work material and thickness, eliminating the need for manual adjustment during cutting and maintaining both high speed and precision.
Solution Approach 2:
The patent dynamically adjusts machining parameters (laser power output, cutting speed, focus position) based on the detected work conditions and pre-stored machining condition tables. This allows the system to optimize performance for each specific cutting scenario, maintaining tracking accuracy even when cutting complex shapes with surface irregularities.
2Adaptability or versatility
If multiple machining condition tables are stored for different materials and thicknesses, then adaptability is improved, but device complexity increases due to larger memory requirements and more complex selection logic
Solution Approach 1:
The patent segments the machining conditions into discrete tables organized by work material type and thickness range. Each table contains pre-optimized parameters for specific material-thickness combinations. The controller simply needs to identify the current work characteristics and select the corresponding table, avoiding the need for complex real-time calculations while maintaining broad adaptability.
3Productivity
If the cutting speed is increased to improve productivity, then processing time is reduced, but the effective range of cutting speed narrows and manufacturing precision deteriorates
Solution Approach 1:
The patent changes multiple parameters simultaneously (laser power output, cutting speed, focus position) based on pre-determined optimal combinations stored in machining condition tables. This coordinated parameter adjustment allows the system to operate at higher cutting speeds while maintaining cut surface quality, as each parameter is optimized for its specific range rather than being independently varied.
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 allows for easy setting of machining conditions, providing a wide operation margin and maintaining desired machining quality, thus enabling stable and efficient laser cutting of complex shapes with reduced processing time and improved surface finish.
Implementation Method 1
a laser beam output from a laser oscillator
Data Source
Figure 1
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AI summary
Laser cutting device (101) includes control unit (120) that controls operations of laser machining robot (130) and laser oscillator (102). A plurality of machining condition tables are stored in memory (110) of control unit (120). Each of the machining condition tables carries data of laser power output and its duty, a usable range of a cutting speed of cutting work (108), the usable range being set based on a speed range in which laser cutting robot (130) can move with given tracking accuracy, and an effective range of the cutting speed and the laser power output that are set so that a cut surface of work (108) meets given finishing conditions. Control unit (120) selects a machining condition table from the plurality of machining condition tables so that the cutting speed and the laser power output meet given conditions, and controls cutting of work (108) based on the selected machining condition table.