Laser Cutting Joint Compensation for Variable Processing Conditions
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Solution Overview
Problem
Existing laser processing machines face challenges in maintaining appropriate joint amounts during sheet metal cutting, leading to issues such as incomplete joint formation, unintended part movement, or difficulty in cutting the joint. These problems arise due to variations in heat input and differences between CO2 and fiber laser oscillators.
Innovation Solution
A joint amount control device and method that analyze processing programs, extract specific codes indicating joint endpoints, add joint information to the program, and generate a joint compensation amount to adjust the joint amount without re-creating the processing program. This device transmits the adjusted program and compensation amount to the numerical control device of the laser processing machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a processing program is created with a specific joint amount, then the joint amount is appropriate under initial processing conditions, but the joint amount becomes inappropriate when processing conditions vary (heat input variation, different laser oscillators)
Solution Approach 1:
The system dynamically adjusts the joint amount during processing by introducing a compensation amount based on actual processing conditions. The NC device modifies the original joint amount (set in the processing program) by adding a compensation value that accounts for variations in heat input, laser oscillator type, and other processing parameters, enabling the joint amount to adapt to changing conditions while maintaining precision.
Solution Approach 2:
The system changes the joint amount parameter during processing by calculating a compensation amount based on processing conditions. The compensation amount is determined by analyzing factors such as heat input variation and laser oscillator type, then applying this compensation to adjust the joint amount dynamically, allowing the same processing program to work across different processing conditions without re-creation.
2Manufacturing precision
If the joint amount is corrected by re-creating the processing program, then the joint amount becomes appropriate, but the productivity decreases due to the time required to re-create the program
Solution Approach 1:
The system performs preliminary analysis of processing conditions and calculates the compensation amount in advance before actual cutting begins. By determining the appropriate compensation value during program preparation or initial setup, the system avoids the need to re-create the entire processing program later, thus maintaining both precision and productivity.
Solution Approach 2:
The system introduces a compensation amount as an intermediary parameter that bridges the gap between the original processing program and the actual processing conditions. This compensation value serves as a mediator that adjusts the joint amount without requiring program re-creation, eliminating the time-consuming process of modifying the original program while still achieving the desired precision.
3Reliability
If the joint amount is increased to ensure joint formation, then the joint is more reliably formed, but the joint becomes difficult to cut
Solution Approach 1:
The system precisely adjusts the joint amount parameter by applying a calculated compensation amount rather than simply increasing it. This allows for fine-tuned optimization where the joint amount is increased only to the extent necessary for reliable joint formation under specific processing conditions, avoiding excessive increases that would make cutting difficult. The compensation amount is determined based on actual processing parameters to achieve the optimal balance.
4Ease of manufacture
If the joint amount is decreased to facilitate cutting, then the joint is easier to cut, but the joint may not form properly and the part may move away from the base material
Solution Approach 1:
The system optimizes the joint amount parameter by applying a compensation amount that ensures sufficient joint formation while maintaining ease of cutting. Rather than simply decreasing the joint amount, the system calculates the precise compensation needed based on processing conditions to achieve the optimal balance between joint formation reliability and cutting ease, preventing both excessive and insufficient joint amounts.
Data Source
AI summary
A processing program analyzer analyzes a processing program and extracts first and second codes included in the processing program and indicating a joint-constituting pair of a first endpoint of a cutting path on a laser cutting start side and a second endpoint of a cutting path on a laser cutting end side. A joint information adder adds joint information indicating the position of at least one of the first code and the second code to the processing program. A joint compensation amount generator generates a joint compensation amount to be set for a joint to be increased or decreased in a joint amount. A transmitter transmits to an NC device the processing program to which the joint information has been added and the joint compensation amount associated with information indicating the joint to be increased or decreased in the joint amount.