Optical Collision Avoidance for Laser Machining Heads
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Solution Overview
Problem
Existing laser machining tools face challenges in collision avoidance due to cut parts tipping over or being flung, leading to unsatisfactory results and increased downtime, as current methods such as leaving micro-bridges, intelligent cutting contours, and fragmentation of inner contours are inefficient and unreliable.
Innovation Solution
A method using optical sensors, such as CMOS cameras, to monitor the machining space, detect changes, and control the laser machining head's movement to avoid collisions by recognizing upright objects and predicting potential collisions through 3D modeling and deep neural networks, enabling early detection and prevention of collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If optical sensors and real-time monitoring are implemented to detect upright objects and prevent collisions, then collision prevention reliability is improved, but device complexity increases
Solution Approach 1:
The patent replaces mechanical collision detection methods with optical sensing systems (cameras, light sensors) and computational image processing. The system uses optical fields to detect upright objects and employs algorithms to analyze image changes, thereby substituting complex mechanical sensing mechanisms with more manageable optical and software-based solutions that improve reliability while controlling overall system complexity.
Solution Approach 2:
The patent introduces an intermediary control system that acts as a mediator between the optical sensors and the laser machining head. This control system processes sensor data, detects potential collisions through image analysis, and generates corrective commands to move the machining head. The intermediary layer simplifies the overall system architecture by centralizing the collision prevention logic and coordinating between sensing and actuation components.
2Reliability
If the laser machining head movement is controlled to avoid collisions in real-time, then collision prevention is improved, but machining productivity decreases
Solution Approach 1:
The patent implements preliminary action by continuously monitoring the machining space before collisions occur. The optical sensors detect upright objects and potential collision risks in advance, allowing the control system to plan and execute avoidance maneuvers proactively rather than reactively. This early detection and preventive approach minimizes interruptions to the machining process, thereby maintaining higher productivity while ensuring collision avoidance.
Solution Approach 2:
The patent employs dynamic control of the laser machining head movement, where the system continuously adapts its motion trajectory based on real-time sensor feedback. The control algorithm dynamically adjusts machining paths to avoid detected upright objects while optimizing for minimal deviation from the original machining plan. This dynamic adaptation allows the system to maintain high productivity by making small, efficient course corrections rather than large, time-consuming interruptions.
3Object-affected harmful factors
If micro-bridges are left to attach cut parts, then collision risk is reduced, but manufacturing precision deteriorates due to incomplete cutting
Solution Approach 1:
The patent applies self-service by using optical sensors to automatically detect the presence and position of upright objects (including partially attached cut parts) and enable the system to autonomously adjust its machining path. The control system independently makes decisions about collision avoidance based on sensor data, eliminating the need for manual intervention or conservative pre-planning that would sacrifice cutting completeness. This autonomous adaptation allows complete cutting while avoiding collisions through real-time path adjustment.
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 significantly reduces reaction times and prevents collisions, providing reliable operation by visualizing the cutting area, determining workpiece conditions, and adapting to geometry and material specifics, thus enhancing machining efficiency and safety.
Implementation Method 1
Monitoring a workpiece in the machining space with at least one optical sensor; Capturing images of the workpiece; Detecting a change in an image of the workpiece
Data Source
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AI summary
The invention relates to a method for collision avoidance of a laser machining head (102) in a machining space (106) of a laser machining tool (100), having the steps of: - Monitoring a workpiece (112) in the machining space (106) with at least one optical sensor; - Capturing images of the workpiece (112); - Detecting a change in an image of the workpiece (112); - Recognising whether the change comprises an object standing upright relative to the workpiece (112); - Checking for a collision between the upright object and the laser machining head (102) based on a predetermined cutting plan and/or the current position (1016) of the laser machining head; - Controlling the drives for moving the laser machining head (102) for collision avoidance in case of recognised risk of collision.