Autonomous laser cutting

Even now we can look back on numerous milestones on the path to autonomous machines. This includes machine functions and assistance systems such as Smart Collision Prevention for collision avoidance, Smart Nozzle Automation, the automatic nozzle changer, as well as Smart Beam Control for intelligent laser beam monitoring. Development is nowhere near finished however, as demonstrated by ground-breaking developments such as the TruLaser Center 7030 full-service laser machine, or the Active Speed Control system for adaptive feed control. It will take a few years to reach full autonomy. Networked production environments and artificial intelligence (AI) will play an important part here.

Every company with a goal of keeping a sharp competitive edge in the age of digitalisation achieves positive results through the automation of processes and the implementation of autonomously operating machines. Intelligent automation solutions for example, create the basis for cost-effective production and offer many advantages in terms of efficiency and transparency. But what good is the fastest machine if, for example, parts tilt? Intelligent assistance systems are the solution for many future challenges. Idle times can quickly take up half the working time of 2D laser cutting machines; this is how long it takes to equip, sort or rectify malfunctions. Autonomously producing laser machines are able to prevent and rectify malfunctions on their own.

An increase in autonomy leads to a decrease in part costs. This is because fewer cases of malfunctions occur during production in general, and if they do occur, they are immediately detected and remedied by the machine – with operator support if required. This has a positive effect on output. Additionally, a significant decrease in rejects is produced. Active Speed Control proactively prevents cutting interruptions caused by fluctuating material quality, for example. This, for example, will prevent the undetected production of reject parts.

Production without malfunctions and rejects is desirable, but not quite realistic; the goal is to decrease the number of items that go to the scrap container. There will, however, always be materials and qualities which are only suitable for precise laser cutting under certain conditions. Whether produced parts require reworking is always dependent on the application. Burr and dross formation cannot be entirely eliminated. We are, however, working towards the goal of using the file as rarely as possible.

Active Speed Control is the latest TRUMPF development on the path to autonomous machines, and provides the entry to partially autonomous laser cutting. It makes parts production more robust, transparent, independent and, most of all, more productive. This is enabled through constant monitoring of the cutting process. With a live-view through the nozzle, the sensor system monitors the light that is emitted during material welding. Based on this so-called process light, it determines whether the welding is going according to plan, identifies the fastest possible feed and adjusts this if required – hundreds of times per second. This creates fewer rejects, more process reliability and less operator involvement with the machine.

Absolutely not. Operator involvement with the machine is decreasing, but for good reason – they will no longer need to shoulder the burden of having to manually monitor the cutting process. This means that they are relieved. The necessity of manual intervention in critical situations is drastically reduced. Instead, the operator receives information (for example with the Active Speed Control system for adaptive feed control) on their mobile device, and can react accordingly. What's particularly advantageous is that the operator is now able to focus on other tasks, such as programming, or preparing for setup or maintenance. They always have absolute control, supported by the laser machine and its assistance systems.