Liquid Jet Cutting Head Motion Sensing for Clog and Collision Detection
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Solution Overview
Problem
Current liquid jet cutting systems require manual monitoring by operators to detect issues like clogged abrasive flow, nozzle collisions, and other failures, which is time-consuming and prone to errors, leading to scrapped workpieces and wasted time due to the inability to quickly and automatically detect failures.
Innovation Solution
The implementation of sensors to monitor movement, sound, temperature, and other characteristics of the cutting system, with data collected and correlated by a computing device to automatically predict and detect wear, failures, and other phenomena, generating alarm signals or shutting down the system when necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual monitoring by operators is used to detect failures, then the system can identify issues like clogged abrasive flow and nozzle collisions, but the monitoring process is time-consuming and prone to errors
Solution Approach 1:
The patent replaces manual mechanical monitoring with automated sensor-based detection systems. Sensors monitor characteristics such as vibration, sound, and pressure to automatically detect failures like clogged abrasive flow and nozzle collisions, eliminating the need for continuous manual observation and reducing both time loss and human error.
Solution Approach 2:
The system enables self-diagnosis through automated monitoring where the cutting system detects its own failures through sensors that continuously monitor operational parameters. The system can automatically identify issues without external human intervention, allowing operators to focus on value-added tasks while the system monitors itself.
2Reliability
If operators continuously monitor the cutting process to detect failures, then detection accuracy improves, but operator bandwidth is reduced and other value-added tasks cannot be performed
Solution Approach 1:
The cutting system performs self-monitoring through integrated sensors that automatically detect failures without requiring operator attention. This allows operators to be freed from continuous monitoring duties and reallocate their time to other value-added tasks, thereby improving overall productivity while maintaining reliable failure detection.
Solution Approach 2:
The system implements automated feedback loops where sensors continuously monitor operational parameters and provide real-time information about system status. This automated feedback mechanism ensures reliable failure detection while eliminating the need for manual observation, allowing operators to maintain higher productivity levels.
3Device complexity
If manual monitoring is used, then the system operation is simpler with fewer components, but failure detection is delayed resulting in scrapped workpieces and wasted operational time
Solution Approach 1:
The patent introduces sensor-based automated monitoring systems that replace manual inspection methods. Although this increases device complexity by adding sensors and data processing capabilities, it dramatically reduces response time to failures by providing continuous automated detection, preventing workpiece scrapping and reducing wasted operational time.
Solution Approach 2:
The system performs preliminary detection of potential failures through continuous sensor monitoring before actual damage occurs. By detecting early signs of problems such as abrasive flow issues or nozzle deviations, the system can alert operators or automatically adjust parameters to prevent workpiece scrapping, thereby reducing wasted operational time despite increased system complexity.
Data Source
AI summary
An operational monitoring system for use with a liquid jet cutting system can include an accelerometer coupled to a cutting head of the liquid jet cutting system. The accelerometer can be configured to generate motion data associated with movement of the cutting head. The system can include a computing device operably connected to the accelerometer and having a memory and a processor. The memory can store a planned data set including expected parameters associated with movement of the cutting head along a planned cut path. In some embodiments, the computing device is configured to receive the motion data from the accelerometer and correlate the motion data to the planned data set.