Laser Cutting Path and Process Planning for Contour Accuracy
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Solution Overview
Problem
Existing laser cutting technologies struggle to maintain high-quality cuts in metal sheets and tubes due to the neglect of kinematic processes, leading to contour errors and quality losses, especially when rapid changes in feed rate are required for corners and small radii.
Innovation Solution
A method for calculating a spatially and time-resolved, combined setpoint data set that coordinates both process setpoints for the laser cutting process and path setpoints for the movement process, taking into account both physical and kinematic processes through the coupling of a process model and a machine model.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rapid changes in feed rate are implemented for corners and small radii, then productivity is improved, but contour errors increase and cutting quality deteriorates
Solution Approach 1:
The system performs preliminary calculation of inertial forces and required feed rate adjustments before the cutting operation. The control unit computes the necessary speed reductions in advance for corners and small radii based on the path geometry and machine kinematics, allowing the system to proactively maintain contour accuracy while maximizing productivity elsewhere.
2Manufacturing precision
If coordinated control of process setpoints and path setpoints is implemented, then cutting quality is improved, but device complexity increases
Solution Approach 1:
The patent merges the process control (laser parameters) and path control (movement trajectory) into a single coordinated control unit. This unified controller simultaneously manages both process setpoints and path setpoints, integrating the two previously separate control functions to achieve improved cutting quality while avoiding the complexity of multiple independent control systems.
Solution Approach 2:
The control unit is designed with multi-functionality, serving both as a path planner and a process controller. It handles kinematic calculations, inertial force compensation, and laser process parameter adjustment within a single system, reducing overall device complexity compared to having separate specialized controllers for each function.
3Manufacturing precision
If inertial forces are compensated through feed rate adjustment, then contour accuracy is improved, but productivity decreases
Solution Approach 1:
The system applies feed rate adjustments locally only where and when inertial forces would significantly impact contour accuracy, such as at corners and small radii. In straight sections and areas with low dynamic requirements, the system maintains higher feed rates, thereby compensating for inertial effects where necessary while preserving productivity where possible.
Data Source
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.