Laser Cutting Path Planning With Dynamic Setpoint Coordination
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Solution Overview
Problem
Current laser cutting technologies for metal sheets and tubes fail to effectively coordinate physical and kinematic processes, leading to quality losses and contour errors due to neglect of inertial forces and dynamic movements, particularly at high feed rates and curved sections.
Innovation Solution
A method for calculating a spatially and time-resolved, combined setpoint data set that integrates process and machine models to coordinate laser cutting and movement processes, accounting for inertial forces and dynamic limitations, using sensor data to adjust setpoints dynamically and prevent contour errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high feed rates are used to improve productivity, then productivity increases, but contour errors and quality losses occur due to inertial forces and dynamic limitations
Solution Approach 1:
The system performs preliminary calculation of inertial forces and dynamic effects before the cutting operation, uses this information to pre-adjust process parameters and feed rate, thereby preventing contour errors before they occur while maintaining high productivity
Solution Approach 2:
The system continuously monitors actual cutting results and machine state, feeds this information back to the control unit, which then dynamically adjusts feed rate and process parameters to maintain contour accuracy while optimizing productivity
2Speed
If rapid changes in feed rate are implemented to navigate corners and small radii, then path traversal capability improves, but inertial forces cause contour errors and quality losses
Solution Approach 1:
The system calculates inertial forces in advance for upcoming path sections including corners and small radii, pre-adjusts feed rate and process parameters accordingly, preventing contour errors before they occur during rapid feed rate changes
Solution Approach 2:
The system dynamically changes process parameters (feed rate, laser power, gas flow) based on calculated inertial forces and path geometry, optimizing the balance between speed capability and contour accuracy during rapid feed rate transitions
3Manufacturing precision
If coordinated control of process setpoints and path setpoints is implemented, then cutting quality and process stability improve, but system complexity increases
Solution Approach 1:
The system merges process control and path control into a unified coordinated control framework, where the control unit simultaneously manages both process setpoints and path setpoints based on integrated calculations of inertial forces and cutting physics, improving cutting quality while consolidating control functions
Data Source
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AI summary
In one aspect, the present invention relates to a control unit (RE) for calculating a spatially and time-resolved, combined setpoint data set (SW-DS) for open- and/or closed-loop control of a laser cutting process during laser cutting with a laser cutting machine (L), wherein a processor (P) is intended to access a process model (PM) in a first memory (SI) via a process interface (P-SS) and a machine model (MM) in a second memory (S2) via a machine interface (M-SS) in order, on the basis of an estimated status data of the laser cutting process and the movement process, to calculate the spatially and time-resolved, combined setpoint data set (SW-DS) with coordinated setpoints for the laser cutting process and setpoints for the movement process, taking into account the read-in sensor data.