Laser Processing Nozzle Gap Control During Power Outage

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Solution Overview

Problem

Conventional laser processing apparatuses require additional mechanical components to prevent the processing nozzle from hitting the workpiece during power outages, leading to increased costs.

Innovation Solution

A laser processing apparatus with a power abnormality detecting section that maintains gap control enabled until a power anomaly is detected, then disables it, using existing actuators to prevent nozzle collision without additional mechanical components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If mechanical components (hydraulic cylinder, engaging member, stopper) are added to prevent processing head dropping during power outage, then safety is improved, but device complexity and cost increase

Engineering Contradiction:

ImprovesafetyVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces mechanical protection mechanisms (hydraulic cylinders, engaging members, stoppers) with an electronic control system that monitors power supply status and automatically adjusts gap control settings. The power supply status detection unit detects power abnormalities, and the gap control unit switches between normal gap control and restricted gap control based on detection results, eliminating the need for additional mechanical components while maintaining safety.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system uses its existing electronic control infrastructure to monitor power supply status and automatically adjust gap control parameters. The control unit leverages its own processing capabilities and existing sensors to detect power abnormalities and switch control modes, making the system self-protecting without requiring external mechanical safety devices.

Inventive Principle:

Principle #25Self-service

2Reliability

If mechanical components (hydraulic cylinder, engaging member, stopper) are added to prevent processing head dropping during power outage, then safety is improved, but manufacturing cost increases

Engineering Contradiction:

ImprovesafetyVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent makes the existing gap control unit perform multiple functions: normal gap control during stable power supply and restricted gap control during power abnormalities. This multi-functionality allows the system to use existing components for safety protection, eliminating the need for separate mechanical safety devices and reducing manufacturing costs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If gap control is continuously enabled during power outage, then processing precision is maintained, but processing head may hit workpiece due to sensor malfunction

Engineering Contradiction:

Improvegap control precisionVSAvoidprocessing head collision

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a power supply status detection unit that continuously monitors power supply conditions and provides feedback to the gap control unit. Based on this feedback, the gap control unit adjusts its operation mode - maintaining normal gap control when power is stable and switching to restricted gap control when power abnormalities are detected, thus preventing processing head collision while maintaining precision during normal operation.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent makes the gap control system dynamic by allowing it to switch between two operational states: normal gap control mode during stable power supply and restricted gap control mode during power abnormalities. This dynamic adaptation enables the system to maintain precision when conditions are favorable while preventing collisions when conditions deteriorate.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS10328522B2Laser processing apparatus capable of retracting processing nozzle upon detection of power outage

Publication Date: 2019.06.25 FANUC LTD

AI summary

A laser processing apparatus including a processing nozzle for irradiating a workpiece with laser beam; an actuator for moving the processing nozzle relative to the workpiece; a distance detector for detecting a gap between the processing nozzle and the workpiece; a power abnormality detecting section for detecting an abnormality in electric power supplied from a power supply unit; a gap control section for controlling the actuator based on a detected value obtained by the distance detector, so as to perform a gap control for adjusting the gap to a target value, during execution of laser processing; and a change control section for maintaining the gap control in an enabled state until a power abnormality is detected by the power abnormality detecting section during execution of laser processing, and for disabling the gap control when a power abnormality is detected by the power abnormality detecting section during execution of laser processing.