XT LASER
Power-Off Resume Function of Smart Laser Cutting Machines: Technical Solutions and Implementation Pathways
Written by Steven, Technical Operations at XT LASERPublished: July 2026 | Read Time: 3mins
TL;DR:The power-off resume function is the core protection mechanism of smart laser cutting machines against sudden power outages. Through three technical pathways—breakpoint position recording, machining state simulation, and precise joint resumption—this function enables the equipment to accurately resume processing from the breakpoint after power restoration, preventing entire sheet scrapping.
Technical Challenges and Solution Approaches
Two technical challenges arise during sudden power outages: first, the laser stops emitting light instantly at the moment of power failure, but the control system experiences delays due to power supply energy storage components, causing deviations in breakpoint position recording; second, the speed is in a state of change at the moment of power failure, making it difficult to achieve precise joint positioning using stroke back-calculation methods.
To address these issues, using time variables rather than stroke variables as the resume reference is the current mainstream solution path. Related patent technology (CN115647611B) proposes a control method based on cumulative processing time recording, avoiding the impact of speed changes at the moment of power failure on resumption accuracy.
Core Implementation Process
During normal processing, the system continuously records cumulative processing time at fixed intervals, storing it in FRAM (Ferroelectric RAM) memory, with data retained after power failure. Upon power restoration, the system reads this time value: if zero, no resumption is needed; if non-zero, the resume process is triggered.
The system acquires the inherent delay of the power controller and adds it to the recorded time to obtain the compensated time for simulation. The equipment then enters a “false start” mode, simulating the pre-power-failure process from the starting position without driving actual motion or laser output. When the accumulated simulation time reaches the compensated time, the system determines that the actual power-off point has been reached and immediately resumes laser output and continues cutting.
After resumption is completed, the system compares edge profile deviations at the breakpoint through image acquisition. If the deviation exceeds the threshold, it performs repair to restore smoothness to the breakpoint edges.
Solution Comparison and Interactive Supplement
The traditional stroke back-calculation solution is based on real-time position coordinates, with resumption accuracy significantly affected by speed changes, requiring high hardware specifications and system load. The time-based solution is based on cumulative processing time, with resumption accuracy independent of speed and good consistency, requiring no special hardware and recording only a single variable, with low system load.
The “Stop Mode” of the Bystronic BCCC system allows operators to manually adjust retract parameters, causing the cutting head to return to a small section before the interruption and recut, further reducing joint errors.
Conclusion
The power-off resume function has become a standardized technical configuration for reducing sheet scrap rates and minimizing production interruption losses. The core implementation pathway is: replacing position coordinates with time variables as the resumption reference, avoiding positioning errors caused by speed changes; determining precise joint points through simulated processing, supplemented by a breakpoint repair mechanism to eliminate rough edges at the joint.
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