Processing Information Acquisition System for Laser and Plasma Machines
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing processing machines face challenges in acquiring and outputting real-time processing information, particularly in laser and plasma processing, due to delays and non-proportional responses in energy or material supply, making it difficult to monitor and control the actual processing state at the processing point.
Innovation Solution
A processing information acquisition system that includes a position information acquisition unit, a feed rate control unit, a feed rate estimation unit, and an output unit, which acquires and estimates the position and feed rate of energy or material at the processing point, and outputs this information to display or storage devices, enabling real-time monitoring and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If open loop control is used for laser beam generation or arc generation and sealant feeding, then device complexity is reduced, but measurement precision and real-time monitoring capability deteriorate because actual processing information cannot be acquired
Solution Approach 1:
The patent introduces an intermediary estimation mechanism that calculates actual processing information (laser output, arc current, sealant feed rate) based on command values and predetermined relationships. This intermediary calculation layer enables real-time monitoring without requiring direct feedback sensors, thus maintaining open-loop simplicity while achieving measurement precision.
Solution Approach 2:
The patent creates a virtual copy of the actual processing state through estimation calculations. Instead of directly measuring physical quantities with sensors, the system generates estimated values that replicate the actual processing information, allowing real-time monitoring and recording without adding complex measurement hardware.
2Measurement precision
If feedback control is implemented to achieve real-time monitoring of processing information, then measurement precision improves, but device complexity increases due to additional sensors and control systems
Solution Approach 1:
The patent uses an intermediary estimation approach that calculates actual processing information from command values using predetermined relationships. This avoids the need for direct feedback sensors and complex control systems while still providing accurate real-time processing information through calculation-based estimation.
Solution Approach 2:
The patent replaces physical measurement systems (sensors, feedback devices) with a calculation-based estimation system. By substituting mechanical/physical measurement infrastructure with computational estimation using predetermined relationships, the system achieves measurement precision without increasing device complexity.
3Productivity
If command values are transmitted to control processing conditions, then productivity increases through automated control, but loss of information occurs because actual processing state differs from commanded state due to response delays and non-proportional relationships
Solution Approach 1:
The patent implements an information feedback mechanism through estimation. By calculating actual processing information (laser output, arc current, sealant feed rate) based on command values and predetermined relationships, the system provides feedback about the actual processing state without requiring physical sensors, thus preventing information loss while maintaining automation.
Solution Approach 2:
The patent creates a virtual copy of the actual processing state through estimation calculations. This virtual copy replicates the true processing information that would otherwise be lost, allowing the system to maintain accurate information about actual processing conditions while continuing to operate in automated open-loop mode.
Data Source
AI summary
A processing information acquisition system in a processing machine which feeds a processing point energy or material, the processing information acquisition system provided with a position information acquisition unit which acquires position information of a feed unit of energy or material, a feed rate control unit which receives a feed condition command of energy or material, converts the feed condition command to a control command which controls a feed of energy or material, and uses the converted control command to control a feed rate of energy or material from the feed unit, a feed rate estimation unit which acquires the control command from the feed rate control unit and calculates an estimated feed rate of energy or material which is fed to a processing point based on the control command, and an output unit which outputs the position information which the position information acquisition unit acquired and the estimated feed rate which the feed rate estimation unit calculated when the feed unit is located at a position corresponding to the position information.