Implementation of real-time optimization control to reduce environmental impact in laser diode assisted sustainable...

Semiconductor laser diode machining has emerged as a disruptive solution improving precision and efficiency in leather cutting making it an indispensable technology in industries such as automotive and aerospace. This study investigates the improvement of Normalized Performance Index (NPI) through the application of Extremum Seeking Control (ESC) to optimize the laser diode cutting process focusing on minimizing carbonization and kerf width while maximizing material removal rate (MRR) to improve the overall process efficiency. As this technology requires less power compared to conventional cutting methods and also reduce the overall carbon footprint promotes sustainability and supports ecofriendly manufacturing practices. The classic control techniques such as Linear-Quadratic Regulator (LQR) controllers and Proportional-Integral-Derivative (PID) controllers find it difficult to adjust to real-time process fluctuations. With adaptive real-time capabilities of ESC this approach offers a possible substitute by dynamically modifying parameters such as Pulse Width Modulation (PWM) and Stand-off Distance (SOD) to preserve the ideal cutting conditions. The impact of ESC on the Material Removal Rate (MRR), kerfwidth and carbonization of leather analysed in the proposed study. The results indicate that ESC considerably enhances the adaptability and consistency of the cutting process reducing carbonization and maintaining constant quality cut across varying conditions. These findings contribute to the advancement of semiconductor laser diode assisted leather cutting and proposes a unique technique for incorporating ESC into manufacturing processes for improved performance contributing to more sustainable and efficient leather cutting practices.