Laser Processing Nozzle Alignment via Reconfigured Surfaces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional laser cutting systems face alignment challenges, particularly with double nozzles, which require high precision and frequent replacement, leading to significant machine downtime and expertise needs due to complex installation and verification processes.
Innovation Solution
The design minimizes misalignment opportunities by reconfiguring surfaces between nozzle components, allowing for improved alignment of the laser beam and nozzle bore, and simplifies installation through reduced interface surfaces and a non-press fit relationship, enabling better radial alignment and uniform fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a double nozzle with two separate flows is used to improve laser cutting performance, then cut quality and material removal efficiency are improved, but alignment complexity and manufacturing precision requirements increase significantly
Solution Approach 1:
The patent merges the alignment functions of the inner and outer nozzle bodies into a unified system. The outer nozzle body includes alignment features that directly align with the laser head, while the inner nozzle body is aligned relative to the outer nozzle body through integrated positioning features. This merging of alignment functions reduces the number of independent alignment operations required and ensures consistent coaxial alignment of both nozzles with the laser beam.
Solution Approach 2:
The patent incorporates preliminary alignment features directly into the nozzle component design. The outer nozzle body includes alignment features that are pre-positioned during manufacturing to ensure proper alignment with the laser head. The inner nozzle body includes positioning features that are pre-configured to align with the outer nozzle body. These preliminary actions eliminate the need for complex post-assembly alignment procedures.
2Adaptability or versatility
If conventional double nozzles with multiple interface surfaces are used, then functional requirements are met, but installation complexity and verification time increase
Solution Approach 1:
The patent extracts the alignment function from the interface between inner and outer nozzle bodies and relocates it to the outer nozzle body's interface with the laser head. The outer nozzle body includes alignment features that directly engage with the laser head, establishing the primary alignment reference. The inner nozzle body is then aligned relative to this established reference through simpler positioning features, reducing the complexity of the interface surfaces.
Solution Approach 2:
The patent segments the alignment function into two distinct levels: (1) alignment of the outer nozzle body with the laser head through dedicated alignment features, and (2) alignment of the inner nozzle body with the outer nozzle body through positioning features. This segmentation allows each interface to be optimized for its specific alignment task, simplifying the overall installation and verification process.
3Reliability
If frequent nozzle replacement is performed to maintain cutting performance, then cut quality is maintained, but machine downtime and technician expertise requirements increase
Solution Approach 1:
The patent incorporates self-aligning features that automatically ensure proper alignment during nozzle installation. The alignment features and positioning features guide the inner and outer nozzle bodies into correct alignment without requiring external alignment tools or complex verification procedures. This self-service capability allows technicians to quickly replace nozzles while maintaining consistent alignment and cut quality, significantly reducing machine downtime.
4Measurement precision
If high precision alignment surfaces are specified to ensure proper nozzle alignment, then alignment accuracy is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent incorporates preliminary alignment features directly into the nozzle component design during manufacturing. The outer nozzle body includes alignment features that are pre-positioned to ensure proper alignment with the laser head, and the inner nozzle body includes positioning features that are pre-configured to align with the outer nozzle body. These preliminary actions eliminate the need for complex post-assembly alignment procedures and high-precision machining of multiple interface surfaces.
Solution Approach 2:
The patent extracts the critical alignment function from the interface between inner and outer nozzle bodies and relocates it to the outer nozzle body's interface with the laser head. This reduces the number of high-precision surfaces required, as the inner nozzle body's alignment is established relative to the already-aligned outer nozzle body through simpler positioning features.
Data Source
AI summary
A double nozzle for a laser processing head includes an inner body portion having an interior surface defining a first bore, and an exterior surface, the bore aligned with a central longitudinal axis of the body. The double nozzle includes an outer body portion having an interior surface defining a second bore that is substantially aligned to the longitudinal axis. The outer body portion is matingly engaged with a region of the exterior surface of the inner body portion. The region between the exterior surface of the inner body portion and the interior surface of the outer body portion defines at least six coaxial fluid flow paths through an interior annular flow volume of the double nozzle. Each fluid flow path is defined at least in part by a corresponding feature formed in at least one of the inner body portion or the outer body portion.