Laser Toolpath Planning Within 5-Axis Machine Stroke Limits
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Solution Overview
Problem
Current laser machining technologies are limited in machining volume due to inefficient utilization of the machine tool's workspace, leading to restrictions on the size of parts that can be machined, especially for large parts requiring 5-axis laser engraving, as the traditional method does not consider the part's geometry and machine stroke during toolpath calculation.
Innovation Solution
A method for computing a machining toolpath that takes into account the part's geometry, image data, and specified machine stroke to optimize the laser head positions, allowing for recalculations if they exceed the machine's stroke limits, ensuring the laser head stays within the machine's capabilities while maintaining quality by adjusting the machining direction and potentially dividing patches to fit within the machine's constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If traditional toolpath computation method is used, then the machining process is simple, but the machining volume is not fully utilized and large parts cannot be machined
Solution Approach 1:
The method performs preliminary simulation of the laser texturing process by taking into account the actual part topology and geometry before machining. This allows the system to optimize the toolpath computation in advance, determining the optimal positioning of the part and laser head to fully utilize the machining volume, rather than using worst-case assumptions that limit the usable volume.
Solution Approach 2:
The invention introduces part positioning data that defines the position of the part to be mounted in the machining area as a new dimension in the toolpath computation. By considering the 5-axis positioning capabilities and actual part geometry in addition to the traditional 3D machining space, the system can optimize the utilization of machining volume and machine large parts that would otherwise exceed the working volume limits.
2Length of stationary object
If the machine tool working volume is used as is, then the machine structure is simple, but the maximum part size that can be engraved is limited
Solution Approach 1:
The system dynamically adjusts the toolpath computation based on the actual part topology and geometry provided as input. Rather than using fixed worst-case assumptions, the computation adapts to the specific part being machined, optimizing the laser head positions and part positioning to maximize the usable machining volume for each particular part, thereby increasing the maximum part size that can be engraved.
Solution Approach 2:
The method changes the parameters used in toolpath computation from fixed worst-case assumptions to actual part-specific parameters including part data defining geometry, image data defining the pattern, and part positioning data. This allows the system to compute optimal laser head positions that fully utilize the machining volume, increasing the maximum part size that can be processed.
3Volume of stationary object
If simulation is based on worst possible part shape, then the simulation is simple, but the potential ablation volume is unnecessarily reduced
Solution Approach 1:
The system performs preliminary simulation of the laser texturing process by taking into account the actual part topology and geometry before machining. This allows the system to optimize the toolpath computation in advance, determining the optimal positioning of the part and laser head to fully utilize the machining volume, rather than using worst-case assumptions that limit the usable volume.
Solution Approach 2:
The invention replaces the traditional mechanical approach of fixed worst-case simulation with a computational approach that uses actual part data. By substituting the mechanical assumption of worst-case geometry with digital modeling based on actual part topology and image data, the system can accurately determine the optimal ablation volume and toolpath without unnecessary conservatism.
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 increases the maximum part size that can be machined by optimizing the machining volume without compromising the quality of the machined parts, allowing for larger and more complex textures to be processed efficiently.
Implementation Method 1
a laser beam is emitted by a laser head installed in a laser machine tool for ablating the material of a part for forming a pattern thereon
Data Source
Figure 1a~1b
Figure 2~4b
Figure 5a~5b
AI summary
The present invention is related to a method for computing a machining toolpath applied for laser machining process, in which a laser beam is emitted by a laser head installed in a laser machine tool for ablating the material of a part for forming a pattern thereon. The method comprises: a. obtaining part data defining the geometry of the part; b. obtaining image data defining the pattern to be machined on the part by ablating the material of the part; c. obtaining specified machine stroke defining the maximum movement of the axes of the machine tool; d. obtaining part positioning data defining the position of the part to be mounted in the machining area of the machine tool; and e. computing the machining tool path based on the part data, the image data, the part positioning data and the specified machine stroke by a computer, wherein the machining tool path includes a plurality of laser head positions.