Laser Nozzle Gap Control for Power Failure Safety
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Solution Overview
Problem
Existing laser processing apparatuses face challenges in preventing the processing nozzle from accidentally hitting the workpiece during power failures, as mechanical stoppage methods may not be reliable in maintaining a safe gap, especially when the gap dimension is small.
Innovation Solution
A laser processing apparatus equipped with a gap sensor, a power monitoring section, and a control action switching section that automatically increases the gap between the processing nozzle and the workpiece when a power anomaly is detected, allowing the nozzle to move away from the workpiece before power is lost, eliminating the need for additional mechanical stoppage mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical stoppage mechanisms are used to prevent the processing nozzle from hitting the workpiece during power failure, then the reliability of preventing nozzle-to-workpiece contact is improved, but the device complexity increases and the gap control precision deteriorates
Solution Approach 1:
The patent replaces mechanical stoppage mechanisms with an electronic control system that uses a power monitoring section to detect power failures and a control action switching section to switch gap control modes. This substitution eliminates the need for additional mechanical components while maintaining safety, thereby reducing device complexity while preserving reliability.
Solution Approach 2:
The patent implements preliminary action by having the control action switching section pre-programmed to automatically switch from first gap control (maintaining constant small gap) to second gap control (increasing gap to safe distance) upon detecting power failure. This preliminary preparation ensures the nozzle is quickly retracted to a safe position before power is completely lost, preventing contact without requiring mechanical intervention.
2Reliability
If mechanical stoppage mechanisms are used to prevent the processing nozzle from hitting the workpiece during power failure, then the reliability of preventing nozzle-to-workpiece contact is improved, but the manufacturing precision deteriorates due to forced stoppage
Solution Approach 1:
The patent applies dynamics by implementing two different gap control modes that can be dynamically switched based on power status. The first gap control maintains a constant small gap for normal precision processing, while the second gap control increases the gap to a safe distance during power failures. The control action switching section enables smooth transition between these modes, preserving manufacturing precision during normal operation while ensuring safety during anomalies.
3Reliability
If the gap is quickly increased during power failure to prevent nozzle-to-workpiece contact, then the reliability of safety protection is improved, but the loss of time in completing the processing task increases
Solution Approach 1:
The patent applies preliminary anti-action by having the control action switching section immediately switch to the second gap control mode upon detecting power failure, which quickly increases the gap to a safe distance. This preliminary protective action prevents nozzle-to-workpiece contact before damage can occur. The system is designed to automatically switch back to the first gap control mode when power is restored, minimizing overall processing time loss while ensuring safety during the brief power failure period.
Data Source
AI summary
A laser processing apparatus including a processing nozzle for irradiating a workpiece with laser beam, a driving mechanism for relatively moving the processing nozzle and the workpiece, and a gap sensor for detecting a gap between the processing nozzle and the workpiece. The apparatus includes a gap control section referring to a measured value detected by the gap sensor and calculating a manipulating variable used for controlling the driving mechanism so as to maintain the gap during execution of laser processing at a first dimension, a power monitoring section monitoring electric power from a power supply and sending an abnormality detection signal to the gap control section when a power abnormality occurs, and a control action switching section switching a control action of the gap control section so as to increase the gap from the first dimension when the abnormality detection signal is sent to the gap control section.