Laser Opening Cutting With Vision Feedback for Shape Accuracy
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Solution Overview
Problem
Existing laser cutting methods using articulated robots struggle to achieve high shape accuracy, particularly when cutting openings at high speeds, as conventional methods are complex and expensive.
Innovation Solution
An apparatus comprising a first and second emitter with different laser powers, a laser head, an image sensor, and a processing unit that compares the laser profile with a predetermined profile to adjust and cut the opening only when the difference is below a threshold, allowing for accurate and efficient cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the moving speed for the articulated robot is increased to improve productivity, then the cutting efficiency is improved, but the shape accuracy of the cutting features deteriorates
Solution Approach 1:
The patent employs a vision system that captures images of the workpiece surface and provides real-time feedback to the control unit. The control unit calculates the actual position and orientation of the workpiece based on the captured images and compares it with the predetermined position and orientation. This feedback mechanism enables dynamic adjustment of the robot's moving speed and cutting path to maintain shape accuracy even at high cutting speeds, thereby resolving the contradiction between productivity and manufacturing precision.
2Manufacturing precision
If the structural stiffness of the articulated robot is improved to ensure cutting accuracy, then the shape accuracy is improved, but the device complexity and cost increase
Solution Approach 1:
The patent replaces the conventional mechanical approach of improving robot structural stiffness with a vision-based feedback control system. Instead of relying on rigid mechanical structures and complex motion compensation mechanisms, the system uses image processing and real-time control algorithms to achieve high cutting accuracy. This substitution of mechanical complexity with computational intelligence reduces device complexity while maintaining or improving cutting precision.
3Manufacturing precision
If a micro-motion platform is added to improve cutting accuracy, then the shape accuracy is improved, but the device complexity and cost increase
Solution Approach 1:
The patent introduces an intermediary vision system that acts as a mediator between the robot and the workpiece. Instead of directly modifying the robot's mechanical structure with complex micro-motion platforms, the vision system captures images of the workpiece surface and provides information about its position and orientation. The control unit uses this intermediary information to calculate and adjust the cutting path, achieving high accuracy without adding mechanical complexity.
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
Enables fast and accurate cutting of openings with improved efficiency at high speeds without the need for complex or expensive modifications to the robotic system.
Implementation Method 1
an image sensor arranged adjacent to a second side of the workpiece opposite to the first side and configured to receive the first laser to form an image of the first laser
Implementation Method 2
a first emitter and a second emitter, a power of a first laser emitted by the first emitter being smaller than a power of a second laser emitted by the second emitter
Implementation Method 3
a processing unit coupled to the image sensor and configured to determine a difference between a profile of the image of the first laser and a predetermined profile of an opening to be cut from the workpiece
Implementation Method 4
to cause the second emitter to emit the second laser to cut the opening if the difference is below a predefined threshold
Data Source
AI summary
Devices and methods for cutting an opening from a workpiece. The apparatus comprises a first emitter and a second emitter, a power of a first laser emitted by the first emitter being smaller than a power of a second laser emitted by the second emitter. The apparatus further comprises a laser head, an image sensor, and a processing unit. The laser head is coupled to the first and second emitters and adapted to move adjacent to a first side of a workpiece and direct the first and second lasers onto the first side. The image sensor is configured to receive the first laser to form an image of the first laser. The processing unit is configured to determine a difference between a profile of the image of the first laser and a predetermined profile of an opening to be cut from the workpiece.