Laser Projection Positioning for Remainder Material Machining
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Solution Overview
Problem
Laser processing systems face challenges in efficiently positioning products on remainder materials without skilled labor, particularly when products have complex shapes or require rotation, leading to potential interference with holes and process defects.
Innovation Solution
A laser processing system that uses a projection means to project an image of the product onto the remainder, with a correction means to adjust the image's position, allowing for accurate determination of the processing area and generation of corrected processing data, preventing interference with skid vertices and ensuring proper positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a worker manually positions the product on the remainder using tape rule and visual inspection, then the positioning can be adjusted to avoid holes, but the process requires skilled labor and takes significant time
Solution Approach 1:
The patent uses a projector to create a visual copy (projection image) of the product outline on the remainder material. This projection image serves as a template that workers can align with the material's coordinate system, eliminating the need for manual measurement with tape rules and visual inspection for positioning accuracy.
Solution Approach 2:
The patent replaces the manual mechanical positioning method (tape rule measurement and visual alignment) with an optical projection system. The projector automatically displays the product outline and coordinate markers on the material surface, substituting complex manual mechanical operations with a simpler optical alignment process.
2Ease of manufacture
If the worker uses tape rule and visual inspection to position the product, then positioning can be achieved, but it is difficult when the product has complicated shape or when the remainder has many holes
Solution Approach 1:
The projector creates a full-scale visual copy of the product outline directly on the remainder material. This allows workers to see the complete product shape and its relationship to existing holes and material boundaries, making it easy to determine feasible positioning without manual measurement of complex geometries.
Solution Approach 2:
The patent uses color-coded projection images to indicate different positioning states. The projection display shows feasible positioning areas in one color and infeasible areas (where products would overlap with holes or exceed material boundaries) in another color, enabling workers to quickly identify valid positioning options without complex analysis.
3Productivity
If the processing program is manually prepared, then the laser processing can be executed, but the processing may come out of the processible area causing the remainder to be discarded
Solution Approach 1:
The system performs preliminary positioning verification by projecting the product outline and coordinate markers onto the remainder before actual laser processing begins. This allows workers to confirm that the planned processing path remains within feasible boundaries and does not intersect with holes or material edges, preventing wasted processing time and material.
Solution Approach 2:
The projection system provides real-time visual feedback about the relationship between the planned laser processing path and the remainder's feasible areas. Workers can observe the projected product outline relative to material boundaries and holes, and adjust positioning before processing begins, ensuring the process remains stable and productive.
4Manufacturing precision
If the laser processing trace overlaps vertexes of the skid, then the remainder and skid are welded together causing process defects
Solution Approach 1:
The projector creates a visual copy of the skid vertex positions on the remainder material surface. These projected vertex markers serve as warning indicators that show workers where the laser processing path must not overlap, preventing harmful welding between the remainder and skid structure.
Solution Approach 2:
The patent uses color-coded projection to distinguish safe and hazardous areas. Skid vertex positions are projected with distinct coloring to alert workers to avoid overlapping these locations during laser processing, preventing welding defects while maintaining processing precision in safe areas.
Data Source
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AI summary
A laser processing system conducts laser processing by irradiating a material with a laser beam. The system projects an image of a product to process on the material, determines whether or not a processing position of the product to process is proper, and if the processing position of the product to process is improper, moves and corrects the projected image on the material, finalizes the position of the projected image with respect to the material, and generates processing data.