Laser Mold Cleaning System Using 3D Image Data
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Solution Overview
Problem
Existing mold cleaning methods, such as shot blasting and plasma cleaning, risk scratching the molding surface, and require manual operation to match the mold shape with pre-recorded data for efficient cleaning, especially for complex shapes.
Innovation Solution
A mold cleaning system with a laser oscillator, a 3D movable laser head, a camera for acquiring three-dimensional image data, and a control device to guide the laser head along the mold surface, allowing for automated cleaning without manual operation and preventing scratches on complex shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If shot blasting cleaning method is used, then cleaning efficiency is improved, but the molding surface is easily scratched
Solution Approach 1:
The patent replaces the mechanical shot blasting system with a laser beam system. The laser beam irradiates the molding surface to remove dirt through thermal effects without mechanical contact, thereby eliminating surface scratching while maintaining cleaning efficiency. The laser head moves along the molding surface controlled by 3D image data, providing non-contact cleaning that resolves the contradiction between cleaning efficiency and surface protection.
2Object-affected harmful factors
If laser beam cleaning method is used, then surface scratching is prevented, but cleaning area per unit time is reduced
Solution Approach 1:
The patent employs a dynamic laser head mounted on a movable arm that can freely move in three dimensions. The laser head position is dynamically adjusted based on 3D image data of the molding surface, allowing the cleaning system to adapt to complex surface geometries and maintain high cleaning coverage. This dynamic positioning capability enables the laser beam to efficiently clean large areas while preventing surface damage.
Solution Approach 2:
The laser cleaning system is designed with universal applicability to various molding surface shapes through 3D image data acquisition and processing. The system can handle different mold types and surface complexities without requiring separate setups, thereby maintaining high productivity across diverse applications while preserving surface integrity.
3Ease of operation
If pre-recorded shape data is used for cleaning, then cleaning process is simplified, but manual operation and shape data matching are required
Solution Approach 1:
The system performs self-service by automatically acquiring 3D image data of the molding surface and using this data to control the laser head movement. The shape data is extracted directly from images captured by the camera, eliminating the need for manual data invocation and matching operations. This automated approach simplifies the cleaning process while maximizing automation extent.
Solution Approach 2:
The system performs preliminary 3D image data acquisition and processing before the actual laser cleaning operation. The shape data is extracted and stored in advance, allowing the laser head to be controlled automatically during cleaning without requiring manual intervention for data matching. This preliminary action streamlines the overall process and reduces manual operations.
4Extent of automation
If 3D image data acquisition is implemented, then automated cleaning control is achieved, but system complexity increases
Solution Approach 1:
The patent introduces a camera as an intermediary device to capture 3D image data of the molding surface. This camera serves as a mediator between the physical mold and the control system, enabling automated laser head positioning without requiring complex direct measurement systems. The image data processing acts as an intermediary step that translates visual information into control commands, simplifying the overall system architecture while achieving high automation.
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 efficient and scratch-free dirt removal from molds with complex shapes by using 3D image data for precise laser head movement, reducing the need for manual shape data invocation and ensuring complete cleaning without leaving dirt traces.
Implementation Method 1
the dirt is removed by the shock wave caused by the irradiation
Data Source
AI summary
Provided is a mold cleaning system. When cleaning a mold, the mold cleaning system acquires three-dimensional image data of a molding surface of the mold by a camera and, on the basis of the acquired image data, the mold cleaning system controls the movement of arms using a control device, moves a laser head along the molding surface while irradiating with a laser beam supplied by a laser oscillator and, as a result, removes dirt adhered to the molding surface.