Adjustment Collar for Auto-Aligning Laser Nozzle and Gas Jet
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In laser machining systems, the relative positions of the laser beam axis and the process gas jet often become misaligned due to nozzle changes or over time, affecting machining accuracy and efficiency.
Innovation Solution
An adjustment collar system with piezoelectric motors allows for precise alignment of the process gas jet nozzle relative to the laser cutting head, using a controller to move the nozzle along X and Y axes to align the gas jet axis with the laser beam axis, utilizing a sacrificial workpiece to determine and correct any misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual alignment methods are used for laser beam and gas jet axes, then device complexity is reduced, but manufacturing precision deteriorates due to misalignment over time and nozzle changes
Solution Approach 1:
The system performs self-alignment by automatically detecting the relative positions of the laser beam axis and gas jet axis, then autonomously adjusting the nozzle position to achieve coaxial alignment without requiring manual operator intervention. The controller executes alignment algorithms and controls actuators to maintain optimal alignment automatically.
Solution Approach 2:
The system continuously monitors the alignment status between laser beam and gas jet axes using detection devices, feeds this information back to the controller, and automatically adjusts the nozzle position through actuators to maintain optimal alignment. This closed-loop feedback mechanism ensures sustained manufacturing precision.
2Manufacturing precision
If frequent manual realignment is performed, then manufacturing precision is maintained, but productivity deteriorates due to time loss
Solution Approach 1:
The alignment system operates continuously during machining operations, automatically maintaining optimal alignment between laser beam and gas jet axes without interrupting the machining process. This eliminates downtime associated with manual realignment and sustains continuous productive operation.
Solution Approach 2:
The system autonomously performs realignment tasks without requiring operator intervention, automatically detecting alignment deviations and correcting them through actuator-controlled nozzle adjustments. This self-service capability eliminates time loss associated with manual realignment operations.
3Productivity
If automated alignment systems are implemented, then productivity is improved by reducing operator intervention, but device complexity increases
Solution Approach 1:
The adjustment collar assembly serves multiple functions: it provides automated alignment control, acts as a mounting structure for the nozzle, incorporates actuators for position adjustment, and includes detection capabilities for monitoring alignment status. This multi-functionality consolidates several components into one integrated assembly, managing complexity.
Solution Approach 2:
The system merges the alignment control functions with the existing nozzle mounting structure by integrating actuators and detection devices into the adjustment collar assembly. This consolidation combines multiple subsystems (alignment control, positioning, detection) into a unified integrated system, improving productivity while managing complexity through component integration.
4Manufacturing precision
If the laser cutting head size is increased to accommodate alignment mechanisms, then manufacturing precision is improved, but the size of the laser cutting head increases
Solution Approach 1:
The alignment adjustment mechanisms are nested within the existing laser cutting head structure. The actuators are positioned inside the adjustment collar assembly, and the nozzle is mounted within the collar, creating a compact nested arrangement that achieves precise alignment functionality without increasing the overall cutting head dimensions.
Solution Approach 2:
The alignment system is segmented into modular components: the adjustment collar assembly, actuators, and detection devices are separate functional modules that can be independently positioned and adjusted within the cutting head structure. This segmentation allows for compact integration of alignment mechanisms without requiring increased overall head size.
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 solution enables automatic and precise alignment of the laser beam and gas jet axes, reducing operator intervention and maintaining coaxial alignment, thereby enhancing machining accuracy and efficiency without increasing the size of the laser cutting head.
Implementation Method 1
the first actuator and the second actuator are piezoelectric motors
Data Source
AI summary
An adjustment collar for a laser machine tool includes a first actuator between an outer housing and an inner collar, the first actuator operable to move the inner collar with respect to the outer housing in the X-axis and a second actuator between the outer housing and the inner collar, the second actuator operable to move the inner collar with respect to the outer housing in the Y-axis.