Laser Nozzle Standby Control for Thermal Expansion Accuracy
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Solution Overview
Problem
The temperature rise in the nozzle due to laser irradiation affects the distance between the nozzle and the workpiece, leading to machining inaccuracies, which existing methods like cooling water flow or metal plating fail to adequately address.
Innovation Solution
Implement a machining process with a standby phase that suspends laser output when the cumulative machining time exceeds a threshold, combined with coolant and assist gas flow to maintain nozzle temperature within safe limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If continuous machining is performed without standby, then productivity is improved, but nozzle temperature rises causing machining precision to deteriorate
Solution Approach 1:
The patent implements periodic standby processes during continuous machining operations. The control unit monitors cumulative machining time and automatically inserts standby periods when thresholds are exceeded, creating a cyclic pattern of machining and cooling that prevents thermal accumulation while maintaining overall productivity.
Solution Approach 2:
The system employs feedback control by monitoring cumulative machining time and automatically determining when standby processes are needed. The control unit uses this information to dynamically adjust the machining schedule, ensuring nozzle temperature remains within acceptable ranges while maximizing continuous operation efficiency.
2Manufacturing precision
If standby process is inserted frequently, then nozzle temperature is stabilized, but productivity deteriorates due to increased idle time
Solution Approach 1:
The patent applies partial standby action by inserting standby processes only when cumulative machining time exceeds predetermined thresholds, rather than using continuous standby. This partial application of cooling maintains nozzle temperature stability while minimizing idle time and preserving machining productivity.
Solution Approach 2:
The system dynamically adjusts machining parameters by changing the timing and duration of standby processes based on cumulative machining time. The control unit modifies the operational schedule to optimize the balance between temperature control and productivity, adapting to different machining conditions and workpiece requirements.
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 approach stabilizes the nozzle temperature, ensuring accurate and continuous machining by preventing thermal expansion and maintaining precise distance control.
Implementation Method 1
machining a workpiece by irradiating the workpiece with the laser beam
Implementation Method 2
the temperature of the nozzle increases due to laser irradiation
Implementation Method 3
a flow path for flowing cooling water is provided in the nozzle, and the cooling water is made to flow during machining
Implementation Method 4
applying metal plating (for example, gold plating or nickel chromium plating) having a high reflectance with respect to the laser
Data Source
AI summary
A laser beam machining method includes performing a machining process including machining a workpiece by irradiating the workpiece with a laser beam from a nozzle, and performing a standby process including suspending output of the laser beam. The standby process starts when a cumulative time of the machining process without the standby process interposed between the machining processes exceeds a threshold time that is predetermined.