Water Jet Cutting Nozzle Control for Corner Quality

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Solution Overview

Problem

Existing water jet cutting technologies face challenges in maintaining consistent cutting quality, particularly with abrasive water jets, as they can result in inclined cutting surfaces and uncut portions on corners due to varying cutting speeds and material thicknesses, requiring manual adjustment of nozzle angles and cutting programs, which is inefficient and inconvenient.

Innovation Solution

A method and apparatus for automatically controlling the nozzle angle based on actual cutting speed, using a control device that calculates optimal cutting speeds for linear and corner portions, assigns these speeds to the cutting program, and adjusts the nozzle attitude to minimize taper angles, ensuring precise cutting without uncut portions and allowing flexible response to changes in cutting speed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If cutting speed is increased to improve productivity, then productivity is improved, but uncut portions occur on corner portions and cutting quality deteriorates

Engineering Contradiction:
Improvecutting speedVSAvoidcutting quality
Core Design Contradiction:
ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies dynamics by making the cutting speed variable rather than constant. The control device dynamically adjusts cutting speed based on the geometric characteristics of the workpiece - using higher speeds for linear portions and lower speeds for corner portions. This dynamic speed adjustment allows the system to maintain high overall productivity while ensuring precise cutting quality at critical locations like corners.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent implements local quality by applying different cutting speeds to different portions of the workpiece. Linear portions are cut at higher speeds for efficiency, while corner portions are cut at lower speeds for precision. This localized differentiation of cutting parameters ensures that each area receives the appropriate speed for its specific geometric requirements, resolving the contradiction between overall productivity and local cutting quality.

Inventive Principle:
Principle #3Local quality

2Manufacturing precision

If nozzle angle is adjusted to eliminate inclination of cutting surface, then cutting quality is improved, but device complexity increases due to manual intervention requirements

Engineering Contradiction:
Improvecutting surface inclinationVSAvoidcontrol system complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies self-service by enabling the control device to automatically calculate and determine the optimal nozzle angle based on the workpiece geometry and cutting conditions. Instead of requiring manual operator intervention, the system autonomously computes the necessary angle adjustments and implements them, thereby eliminating inclination of the cutting surface while avoiding the complexity of manual control procedures.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The patent implements feedback by using the control device to continuously monitor cutting progress and automatically adjust nozzle angle in response to detected conditions. The system receives information about workpiece geometry and cutting state, processes this data, and automatically modifies the nozzle angle to maintain optimal cutting quality, reducing the need for manual intervention and simplifying the overall control process.

Inventive Principle:
Principle #23Feedback

3Manufacturing precision

If multiple cutting programs are created to accommodate different cutting speeds and angles, then cutting quality is maintained, but ease of operation deteriorates due to program management complexity

Engineering Contradiction:
Improvecutting quality consistencyVSAvoidprogram management
Core Design Contradiction:
Manufacturing precisionVSEase of operation

Solution Approach 1:

The patent applies universality by creating a single cutting program that can adapt to various cutting conditions through automatic parameter adjustment. Rather than requiring separate programs for different cutting speeds and angles, the control device universally handles diverse cutting scenarios by dynamically modifying speed and angle parameters based on real-time workpiece geometry, thereby maintaining cutting quality while simplifying program management.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent implements parameter changes by automatically modifying cutting parameters (speed, angle, flow rate) during the cutting process based on detected workpiece characteristics. This dynamic parameter adjustment allows a single cutting program to effectively handle multiple cutting scenarios, eliminating the need to create and manage multiple separate programs while maintaining consistent cutting quality across different conditions.

Inventive Principle:
Principle #35Parameter changes

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 solution enables automatic control of the cutting process to achieve desired cutting quality with no uncut portions on corners, allowing for flexible adjustments in cutting speed and time, improving efficiency and reducing the complexity of managing multiple cutting programs.

Implementation Method 1

a jet (hereinafter referred to as the 'water jet') is obtained by pressurizing water to a high pressure

Methodology Applied
Scientific EffectPressurisation: Pressurisation

Implementation Method 2

the water jet is mixed with abrasive inside the nozzle, thus producing a water jet with abrasive (abrasive water jet)

Methodology Applied
Scientific EffectMixing:

Implementation Method 3

The abrasive water jet is used to cut a variety of materials

Methodology Applied
Scientific EffectAbrasion: Abrasion

Implementation Method 4

the water jet is mixed with abrasive inside the nozzle, thus producing a water jet with abrasive (abrasive water jet)

Methodology Applied
Scientific EffectJet Erosion: Jet Erosion

Data Source

PatentUS9889538B2Method and apparatus for water jet cutting
Publication Date: 2018.02.13 SUGINO MACHINE
  • US9889538B2 patent drawing
  • US9889538B2 patent drawing
  • US9889538B2 patent drawing

AI summary

To control cutting process with cutting quality to obtain product without any uncut portion on a corner portion, and to respond to a change in cutting speed. Water jet cutting performed by: inputting a cutting program, set cutting speed, cutting parameters; calculating cutting speed matching the cutting quality; calculating cutting shape from the cutting program and dividing the cutting shape into a linear portion and a corner portion; calculating a corner cutting speed for the corner portion on the basis of a shape of the corner portion within range from the calculation cutting speed to the set cutting speed, set cutting speed equal to or higher than the calculation cutting speed; set cutting speed and the corner cutting speed to the linear portion and the corner portion, respectively, in the cutting program; moving the nozzle relative to the workpiece on the basis of the cutting program assigned with cutting speeds.