Laser Plotter Path Planning for Precise Bus-Based Laser Timing
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Solution Overview
Problem
Conventional laser plotter architectures require high hardware and software engineering efforts due to direct connections between laser control modules and position encoders, leading to inefficient synchronization of laser activation with axle positions.
Innovation Solution
Implementing a method where path planning is performed offline by a computer unit or cloud solution, with estimated axle positions calculated at future points in time using an industrial bus, allowing synchronization of laser activation with axle positions without direct connections, using a standardized industrial bus like EtherCat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a stand-alone control solution with direct connection between laser control module and position encoder is used, then precise laser activation timing is achieved, but hardware and software engineering effort increases significantly
Solution Approach 1:
The patent introduces an intermediary estimation mechanism that calculates future axle positions based on current position and speed data. This mediator allows the laser control module to operate independently from direct position encoder connections while maintaining precise timing by predicting where the axle will be at future time points, thus resolving the contradiction between precision and complexity.
Solution Approach 2:
The system performs preliminary calculations of future axle positions before actual laser activation is needed. By pre-computing position estimates at future time points and storing them, the system prepares activation data in advance, enabling precise laser timing without requiring complex real-time direct connections to position encoders.
2Device complexity
If standardized industrial bus with cyclic sampling is used for communication, then hardware complexity is reduced, but laser synchronization with axle position becomes inaccurate due to sampling delays
Solution Approach 1:
The system pre-calculates axle positions at future time points corresponding to when laser activation will occur. By computing these future positions in advance using current speed and position data, the system compensates for the inherent delays in cyclic sampling, ensuring accurate laser positioning despite using standardized industrial bus communication.
Solution Approach 2:
The estimation mechanism dynamically adjusts future position calculations based on real-time speed and position data received through the industrial bus. This dynamic approach allows the system to adapt to changing motion conditions while maintaining synchronization accuracy, resolving the contradiction between using simplified standardized communication and achieving precise laser positioning.
Data Source
AI summary
A laser plotter and method for operating a laser plotter for cutting, engraving, marking and/or lettering a workpiece are disclosed. When an irradiation source is activated, a laser beam is directed via deflection elements to a focusing unit. A control unit performs the control on the basis of set parameters and/or a loaded job. The data, in particular job, are received via a computer unit, and a calculation of the path planning is performed offline by the computer unit or externally by a cloud solution or component. The path planning and other data are transferred to a PLC controller or soft PLC, from which at the sampling times, the individual target data, in particular the path planning and other data, such as the speed, are then sent step by step via an industrial bus to at least the modules for axle control and laser control.