Smart Corner Laser Cutting with Dynamic Parameter Conversion
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Solution Overview
Problem
Current laser cutting technologies face challenges in achieving high-quality cuts with efficient resource use, particularly in adapting dynamic cutting parameters to varying speeds and curvatures, leading to unsatisfactory results and increased gas consumption.
Innovation Solution
A computer-implemented method calculates a second cutting parameter data set based on a movement profile object, dynamically adjusting focus position, gas pressure, and other parameters as a function of cutting speed and acceleration, using a conversion algorithm to optimize cutting parameters for different contour geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dynamic cutting parameters are adapted as a function of speed and acceleration, then cutting quality is improved, but device complexity increases
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting cutting parameters (focus position, gas pressure, laser power, pulse width, pulse frequency, nozzle distance) as a function of speed and acceleration. The control system modifies these parameters in real-time based on the movement profile object, which contains speed and acceleration data for different contour sections. This allows optimization of cutting quality for both straight cuts and corners/radii without requiring hardware modifications.
Solution Approach 2:
The patent implements dynamics by making cutting parameters variable during the cutting process rather than static. The system extracts a movement profile object that contains speed and acceleration information, then uses this to dynamically adjust cutting parameters. This dynamic adaptation enables the system to respond to changing geometric conditions (straight lines vs. curves) and varying speeds, improving quality while maintaining productivity.
2Productivity
If higher feed rates are used for straight cuts, then productivity is improved, but cutting quality deteriorates in corners and radii
Solution Approach 1:
The patent applies local quality by differentiating cutting parameters for different sections of the cutting contour. The system identifies corners and radii in the movement profile object and applies specific parameter adjustments for these locations versus straight sections. For example, gas pressure and focus position are adjusted specifically for corner sections, while straight sections can maintain higher feed rates. This localized optimization ensures high quality in corners without sacrificing overall productivity.
Solution Approach 2:
The patent segments the cutting contour into different geometric sections (straight lines, corners, radii) based on the movement profile object. Each segment is then processed with optimized cutting parameters appropriate to its geometric characteristics. The control system divides the cutting path into sections and applies different parameter sets for each type of section, allowing high feed rates for straight segments while maintaining quality for corner segments.
3Manufacturing precision
If cutting parameters are optimized for corners and radii, then cutting quality is improved, but gas consumption increases
Solution Approach 1:
The patent applies partial action by adjusting gas pressure only when and where needed - specifically for corner and radius sections - rather than maintaining high gas pressure throughout the entire cutting contour. The system identifies corner sections in the movement profile object and increases gas pressure only for these specific locations, while maintaining lower gas pressure for straight sections. This partial application of enhanced gas pressure achieves the necessary quality improvement in corners without the excessive gas consumption that would result from uniformly high pressure throughout.
Data Source
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AI summary
In one aspect, the present invention relates to a computing unit (RE) for executing a conversion algorithm, having an interface (UI) for acquiring a first cutting parameter data set (1SP); and having a processor (P) which is designed to extract a movement profile object (bpo) and which is also designed to execute a conversion algorithm that is stored in a memory of the electronic computing unit (RE) so that it can be loaded and/or executed to calculate and provide the second cutting parameter data set (2SP) to the acquired first cutting parameter data set (1SP), wherein the second cutting parameter data set (2SP) is calculated as a function of the extracted movement profile object (bpo).