Laser Marker Trigger Timing Buffer for Tight Workpiece Spacing
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Solution Overview
Problem
Existing laser processing devices face inefficiencies in processing time and cost due to the requirement for a minimum interval between workpieces, which limits the ability to reduce the conveyance interval and increases processing time and cost for large numbers of workpieces.
Innovation Solution
A laser processing device incorporating a trigger sensor, encoder, FIFO memory, and printing control unit that uses a free running counter to store and read out trigger timing count values to recognize the position of the next workpiece and perform printing only when it reaches the printing position, allowing for reduced intervals between workpieces without increasing processing cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the distance d between the trigger sensor and the laser marker device is ensured to avoid detection errors, then the reliability of workpiece detection is improved, but the interval between workpieces must be greater than d, which increases the processing time and reduces productivity
Solution Approach 1:
The trigger sensor detects workpieces in advance at a distance d from the laser marker device, and the control unit stores the detection timing information in advance. This preliminary detection and storage of timing data allows the system to prepare for upcoming workpieces without waiting for them to reach the processing position, enabling continuous high-speed operation while maintaining reliable detection.
Solution Approach 2:
A FIFO first-in-first-out memory unit is introduced as an intermediary between the trigger sensor and the control unit. This memory unit temporarily stores the timing information of detected workpieces, allowing the control unit to retrieve and process this information at the appropriate moment without requiring the workpiece interval to be greater than distance d, thus decoupling the detection reliability requirement from the processing speed limitation.
2Productivity
If the interval between workpieces is reduced to increase productivity, then the processing time is shortened, but detection errors occur due to smoke adhesion on the trigger sensor
Solution Approach 1:
The trigger sensor performs detection in advance at a safe distance from the laser processing zone where smoke adhesion is minimal. The detection results are stored with timing information, allowing the system to process workpieces at high speed intervals without compromising detection accuracy, as each workpiece is detected before it enters the hazardous smoke-filled zone.
Solution Approach 2:
The control unit uses the stored timing information from the FIFO memory to determine when to perform laser processing on each workpiece. This feedback mechanism ensures that processing occurs at the correct moment for each individually detected workpiece, maintaining high productivity while preventing detection errors that would occur with continuous high-speed operation in smoke-filled environments.
3Device complexity
If the trigger signal for the next workpiece is canceled during ongoing printing processing, then processing simplicity is maintained, but the interval between workpieces cannot be reduced, increasing processing time and cost
Solution Approach 1:
The trigger sensor and FIFO memory unit capture and store timing information for multiple upcoming workpieces in advance, before the current processing cycle completes. This preliminary capture of multiple workpiece timing data allows the control unit to efficiently manage batch processing of large numbers of workpieces without requiring complex real-time decision logic, thereby improving productivity while maintaining reasonable control complexity.
Solution Approach 2:
The FIFO memory unit acts as an intermediary buffer that decouples the simple trigger signal generation from the complex processing scheduling. This buffer stores timing information for multiple workpieces, allowing the control unit to efficiently manage batch processing sequences without requiring complex real-time control logic, thus improving batch processing efficiency while maintaining control logic simplicity.
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 configuration enables shorter printing processing times for multiple workpieces by accurately determining the position and timing of each workpiece, allowing for reduced intervals between them without increasing processing costs or errors.
Implementation Method 1
a trigger sensor 13 for detecting workpieces A to E transferred by the workpiece conveying device 12 at a workpiece detection position wd separated from a printing position ac by a distance d in a conveyance direction of the workpiece conveying device 12
Implementation Method 2
an encoder 14 for outputting a pulse signal p based on a transfer distance of the belt conveyor 12
Implementation Method 3
the workpiece is irradiated with laser light L at the timing when each workpiece moves to a printing position which is at a lower position of the laser marker device 1, and printing or drawing processing is performed
Implementation Method 4
irradiating a workpiece with laser light to perform printing or drawing
Data Source
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AI summary
A laser marker device (11) includes: a free running counter (16) configured to output a free count value (Cf) obtained by counting the number of pulses of a pulse signal; a FIFO memory (15) configured to sequentially store the free count value as a trigger timing count value every time a trigger signal (tr) is output from a trigger sensor (13); a printing control unit (17, 18) configured to sequentially read out the trigger timing count value from the memory in order of storage, recognize a position of a workpiece to be printed next, and perform printing processing with respect to the workpiece if the workpiece is conveyed to the printing position.