Multi-Pass Beveling with Single Torch NC Machine
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Solution Overview
Problem
Current steel cutting technologies face challenges in efficiently beveling steel plates for welding, as existing solutions are complex, require extensive programming, and struggle with multi-pass beveling, especially when dealing with hard materials like stainless steel, often necessitating manual grinding and being costly.
Innovation Solution
A method and system that combines weld preparation information with electronic part descriptions to generate multi-pass contours for a numerical control machine, allowing for automatic conversion of CAM files into NC programs without human intervention, using a single cutting tool to create efficient and machine-independent cutting paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multi-pass beveling is attempted with single torches, then productivity is improved by eliminating triple torch complexity, but the solution becomes too complex to program and operate
Solution Approach 1:
The beveling process is divided into multiple passes, each creating a portion of the final bevel geometry. The software segments the complex multi-pass operation into manageable contour generations that can be automatically programmed, reducing operational complexity while maintaining productivity benefits.
Solution Approach 2:
Special purpose software acts as an intermediary between the operator and the NC machine, automatically generating the complex multi-pass contour programs. This intermediary handles the programming complexity internally, presenting a simplified interface to the user while producing the required complex toolpaths.
2Productivity
If triple head oxy acetylene torch is used, then beveling capability is achieved in a single pass, but the system becomes expensive and difficult to operate due to spinning requirements
Solution Approach 1:
Instead of using multiple torches spinning to achieve beveling in one pass, the invention inverts the approach by using a single stationary torch that makes multiple passes. This inversion eliminates the mechanical complexity of spinning triple torches while achieving the same beveling result through sequential operations.
Solution Approach 2:
The beveling process is replicated across multiple passes of the same torch rather than using multiple torches simultaneously. Each pass copies the beveling action at different positions and angles, accumulating the final bevel geometry through repeated application of the same tool.
3Manufacturing precision
If manual or semi-manual edge preparation is used, then weld readiness is achieved, but time is lost in the manufacturing process
Solution Approach 1:
Manual mechanical edge preparation using grinders or small machines is replaced with an automated NC torch system that performs beveling through controlled thermal cutting. This substitution eliminates manual intervention and significantly reduces preparation time while maintaining or improving weld readiness quality.
Solution Approach 2:
The edge preparation process changes from mechanical removal of material to thermal cutting with controlled parameters. By adjusting torch angle, feed rate, and gas flow, the system achieves precise bevel geometries automatically, replacing time-consuming manual grinding with parameter-controlled automated cutting.
4Ease of manufacture
If bevel information is kept separate from part drawing, then drawing simplicity is maintained, but communication of weld preparation information becomes difficult
Solution Approach 1:
The system merges bevel information with part drawing data into a unified digital model. Weld preparation parameters are integrated directly into the CAD/CAM workflow, allowing automatic extraction of both geometry and bevel requirements without separating the information, thus preventing loss of critical weld preparation data.
Solution Approach 2:
The software system serves multiple functions: it handles part geometry, generates toolpaths, and manages weld preparation parameters all within a single integrated platform. This multi-functionality eliminates the need for separate information channels while maintaining drawing simplicity through unified data structures.
Data Source
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AI summary
The present application relates to a system (1300), a method and software products generating multi-pass contours for controlling a numerical control (NC) machine (1352) to cut out a part with weld preparation. Weld preparation information is combined with an electronic description of the part to form an enhanced electronic file. Multi-pass contours, usable to control an NC machine (1352) to cut out the part with at least one bevel, are generated based upon the enhanced electronic file.