Segment-Specific Laser Beam Shaping for High-Speed Cutting Quality
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Solution Overview
Problem
Laser cutting processes face challenges in optimizing productivity and quality, as higher feed rates often compromise cutting quality due to the interaction of laser energy distribution with material, leading to issues like kerf dimensions and heat accumulation.
Innovation Solution
A method for dynamically varying the laser beam shape during cutting using a dynamic beam shaping module, which allocates specific beam shapes to different cutting segments based on their geometry and requirements, utilizing a trained neural network model for optimal energy distribution and contour error compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the feed rate of the laser cutting head is increased to improve productivity, then productivity is improved, but cutting quality deteriorates due to insufficient energy distribution and heat accumulation issues
Solution Approach 1:
The patent applies dynamic beam shaping (DBS) to continuously vary the laser beam profile during cutting operations. Instead of using a fixed beam shape, the system dynamically adjusts beam parameters such as spot size, intensity distribution, and focal position in real-time based on cutting conditions, enabling quality maintenance at higher feed rates
Solution Approach 2:
The system changes multiple beam parameters simultaneously including spot size, intensity distribution, focal position, and beam shape. These parameter changes are coordinated to optimize energy coupling with the material at different feed rates, allowing the system to maintain cutting quality while increasing productivity
2Use of energy by moving object
If a small spot size is used to concentrate laser energy, then energy density is improved, but kerf dimensions become insufficient leading to poor melt ejection
Solution Approach 1:
The system dynamically adjusts the spot size during cutting, using smaller spot sizes when high energy concentration is needed and larger spot sizes when adequate kerf width is required. This temporal variation allows the beam to provide both concentrated energy and sufficient kerf dimensions at different moments in the cutting process
Solution Approach 2:
The dynamic beam shaping module periodically modulates the beam parameters including spot size and intensity distribution. This periodic action creates temporal variations in energy delivery that allow concentrated heating followed by adequate energy distribution for proper melt ejection and kerf formation
3Manufacturing precision
If static beam shaping is used to optimize energy distribution, then beam profile is optimized, but the beam shape cannot be changed during processing
Solution Approach 1:
The patent transitions from static beam shaping to dynamic beam shaping where the beam profile can be changed in real-time during processing. The dynamic beam shaping module allows continuous adjustment of beam parameters to adapt to different cutting conditions, materials, and positions, providing both optimized energy distribution and beam shape variability
Solution Approach 2:
The dynamic beam shaping system serves multiple functions: it optimizes energy distribution like static shaping, but additionally provides real-time adaptation to varying cutting conditions, handles different materials and thicknesses, and maintains quality across different feed rates. This multi-functionality resolves the limitation of static shaping
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 improves cutting quality and productivity by ensuring appropriate energy distribution and preventing heat accumulation, allowing for precise control of kerf dimensions and maintaining process stability across varying material types and thicknesses.
Implementation Method 1
laser cutting by means of a laser cutting machine
Implementation Method 2
transforming absorbed laser energy into heat
Implementation Method 3
automatic calculation... an allocation to a dynamic laser beam shape... based on the segment geometry and characteristics
Data Source
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AI summary
In one aspect the invention relates to a control unit (100) for determining a dynamic laser beam shape for controlling a laser cutting machine (L), which is provided with e.g., a dynamic beam shaping module for varying the shape of the laser beam, with: A cutting plan interface (101), which is configured for receiving a cutting plan to be processed for cutting out parts of a workpiece, wherein each part is defined by a cutting contour, wherein the cutting contour is segmented in a set of cutting segments, wherein each workpiece is characterized by a property indicator, selected from the group consisting of a material indicator and/or a thickness indicator; An interface (102) to a shape storage (ShS) with a stored set of dynamic laser beam shapes, in particular more than two; A processor (P) which is configured for automatically calculating for each of the cutting segments iteratively for all parts to be cut out of the workpiece an allocation to a dynamic laser beam shape of the set of dynamic laser beam shapes, stored in the shape storage (ShS), wherein calculating the allocation (S3) is based on the property indicator of the workpiece and is specific for the respective cutting segment; and wherein the processor (P) is further configured for providing control instructions (Cl) via an output interface (103) for controlling the laser cutting machine (L) for executing the received cutting plan by applying the determined dynamic laser beams shapes for each cutting segment specifically.