Laser Machining Nozzle Controller Approach Time Reduction
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Solution Overview
Problem
Laser machining devices face challenges in efficiently positioning nozzles relative to workpieces due to unknown workpiece states, leading to potential collisions and decreased accuracy, which results in inefficiencies and defects in the machining process.
Innovation Solution
A controller system that specifies a target gap amount with tolerance, detects the actual gap, and determines the completion of nozzle positioning based on contact and operational state, allowing subsequent processes to commence when positioning is expected to be completed, thereby reducing approach time and preventing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the approach operation is carried out at a low speed, then the collision of the nozzle can be prevented, but the efficiency substantially decreases
Solution Approach 1:
The patent applies dynamic speed adjustment by switching between high-speed approach mode and low-speed approach mode based on real-time gap detection. The nozzle moves at high speed when the gap is large and switches to low speed when the gap sensor detects proximity to the workpiece, optimizing both efficiency and safety
Solution Approach 2:
The patent changes the motion parameter (speed) of the nozzle based on the detected gap amount. When the gap amount detected by the sensor exceeds a predetermined value, high-speed approach is maintained; when it falls within the predetermined value, low-speed approach is activated to prevent collision
2Productivity
If the approach operation is carried out at a high speed, then the efficiency is improved, but the risk of nozzle collision with the workpiece increases
Solution Approach 1:
The patent implements feedback control using a gap sensor to continuously monitor the distance between the nozzle and workpiece. The detected gap amount is fed back to the control unit, which adjusts the nozzle speed accordingly to maintain safe operation while maximizing efficiency
Solution Approach 2:
The patent performs preliminary high-speed approach to quickly reduce the gap, then switches to low-speed approach when the gap sensor detects proximity. This preliminary action allows the system to cover most of the distance quickly while only using slow speed for the critical final approach
3Manufacturing precision
If the nozzle positioning waits for complete precision, then the positioning accuracy is ensured, but the subsequent process starts later
Solution Approach 1:
The patent applies partial action by determining that positioning is sufficient for the subsequent process to begin when the gap amount is within the predetermined value, without requiring complete precision. This allows the subsequent process to start earlier while maintaining adequate positioning accuracy
Data Source
AI summary
A controller of a laser machining device according to the present invention includes a positioning completion determining part for determining whether or not positioning of the nozzle is completed, a completion expectation determining part for determining whether or not the completion of the positioning of the nozzle can be expected, and a subsequent process determining part for determining whether or not a subsequent process can be carried out in the state where the completion of the positioning of the nozzle is expected. If the subsequent process can be carried out when the completion of the positioning of the nozzle is only expected, the subsequent process is carried out immediately when it is determined that the completion of the positioning of the nozzle can be expected. If the subsequent process cannot be carried out, the subsequent process is carried out only after the positioning of the nozzle is completed.