Laser Processing Suction Flap Timing for Contamination Control
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Solution Overview
Problem
Laser processing machines face significant contamination issues due to increased laser power and cutting speed, leading to premature machine component failures and inefficient waste product removal, as existing suction systems rely solely on the bridge position for flap control, which is inadequate, especially in larger installations.
Innovation Solution
A suction device with a control system that detects the position and operating state of the laser processing head using a processing plan to predictively control flaps and fan operation, optimizing airflow and minimizing contamination by opening flaps before the cutting process begins and maintaining airflow after processing to ensure efficient waste removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If flaps are controlled solely based on bridge position, then the control system is simple, but the suction efficiency is insufficient especially in larger installations
Solution Approach 1:
The control system opens flaps in advance based on the processing plan before the laser processing head actually reaches the corresponding position. This preliminary action ensures that the air flow is already established when waste products are generated, significantly improving suction efficiency without requiring complex real-time detection systems
Solution Approach 2:
The system dynamically adjusts flap opening timing by calculating future positions from the processing plan. Instead of static position-based control, the system creates a dynamic control strategy that anticipates processing locations and optimizes air flow establishment timing adaptively
2Productivity
If flaps are opened early to improve suction efficiency, then waste removal is enhanced, but energy consumption increases
Solution Approach 1:
The system applies partial action by opening only the specific flaps corresponding to the future processing position rather than all flaps simultaneously. This selective approach maintains adequate suction efficiency while minimizing unnecessary energy consumption from operating excess flaps
Solution Approach 2:
The control system changes the timing parameter of flap operation based on processing plan analysis. By optimizing the opening time to be just before processing rather than continuously open, the system achieves effective waste removal while reducing overall energy consumption through parameter optimization
3Manufacturing precision
If thermal influence on cut material is minimized by not opening flaps during positioning, then material quality is improved, but waste product distribution in cutting chamber increases
Solution Approach 1:
The system establishes air flow in advance by opening flaps before processing begins, creating a pre-positioned suction field. This preliminary air flow establishment ensures that when the laser starts cutting, waste products are immediately drawn away, preventing their distribution throughout the cutting chamber while maintaining thermal stability during positioning
4Loss of energy
If suction power is minimized for economic and ecological reasons, then operational costs are reduced, but contamination control becomes insufficient
Solution Approach 1:
By opening flaps in advance based on the processing plan, the system creates optimal air flow conditions before waste products are generated. This timing optimization maximizes the effectiveness of the suction system, allowing lower overall suction power to achieve the same contamination control效果
Solution Approach 2:
The system optimizes the timing parameter of flap operation to coincide precisely with waste generation events from the processing plan. This parameter optimization ensures that suction power is applied most effectively when needed, reducing overall energy consumption while maintaining adequate contamination control
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 minimizes contamination within the machine and workpieces, extends machine component lifespan, and reduces energy consumption by optimizing suction flow and flap control based on real-time and predictive data, ensuring efficient and targeted removal of gaseous and dusty waste products.
Implementation Method 1
a fan (122) and a plurality of flaps (126) which are to be opened selectively in order to generate an air flow
Data Source
AI summary
The present disclosure relates to a suction device configured for a laser processing machine with a laser processing head which can be moved over a workpiece holder, with a fan and several flaps which are to be opened selectively to generate an air flow and which are in communication with the fan, and with a control configured to detect the position and operating state of the laser processing head and to control the flaps as a function of the detected position and the operating state of the laser processing head.