Laser Model Interpolation for Consistent Cut Depth
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Solution Overview
Problem
Current monitoring devices for high-speed laser processing are not sufficiently accurate, requiring expensive, highly trained technicians and often failing to achieve consistent cut depths and widths at varying material speeds due to inherent delays and nonlinearities in the laser and control systems.
Innovation Solution
A laser cutting system that models and adjusts the output power at varying frequencies and duty cycles to maintain consistent cut depths and widths by interpolating necessary parameters for pulse width modulation, ensuring consistent energy density across different material speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high process velocities are used to increase productivity, then material processing speed improves, but monitoring accuracy and control precision deteriorate
Solution Approach 1:
The patent introduces a modeling intermediary that creates a virtual representation of the laser system's behavior. This model acts as a mediator between the control system and the physical laser, allowing predictions of laser output characteristics without requiring real-time high-speed monitoring of the actual laser beam. The model interpolates between predetermined calibration points to provide accurate predictions at any given process velocity, thus resolving the contradiction between high speed processing and measurement accuracy.
Solution Approach 2:
The system performs preliminary calibration by establishing a model at predetermined lower speeds before actual high-speed processing. During calibration, the system measures laser output characteristics at various duty cycles and frequencies to build a predictive model. This preliminary action stores the necessary information in the model, enabling accurate control at high speeds without requiring real-time measurement capabilities at those speeds.
2Productivity
If laser power is increased to maintain cut depth at higher speeds, then cutting speed improves, but energy density control precision deteriorates due to nonlinearities
Solution Approach 1:
The patent transforms the control approach by changing from direct power adjustment to model-based parameter interpolation. Instead of directly controlling laser power at high speeds (where nonlinearities cause precision loss), the system uses a pre-built model that accounts for the nonlinear relationship between duty cycle, frequency, and actual laser output. The model interpolates between predetermined calibration points to predict the exact duty cycle and frequency settings needed to achieve consistent energy density and cut depth at any given speed.
3Device complexity
If conventional linear duty cycle control is used, then system simplicity is maintained, but cut consistency deteriorates due to laser nonlinearity
Solution Approach 1:
The patent creates a virtual copy or model of the laser system's nonlinear behavior through predetermined calibration measurements. This model copy captures the complex nonlinear relationships between control parameters and actual laser output without requiring complex hardware modifications. During operation, the model is used to calculate the appropriate duty cycle and frequency settings, providing consistent cut quality while maintaining relatively simple control system architecture.
Data Source
AI summary
Laser processing device and method that stores characterization information representing specifics of a specific laser used for processing a material and forms a model to control the laser based on the laser performance specifics. This control sets a spacing between leading edges of sequential pulses of optical energy output by the laser, that when output by the laser, creates a laser power output with a consistent amount of pulse overlap between the sequential pulses, e.g., 50% overlap. This control is specific to the specific laser and creates a very consistent processing using the laser, e.g., a cut.