Universal device for creating predetermined breaking lines in vehicle assemblies

Abstract

The invention relates to a universal device for creating a predetermined breaking line in a vehicle assembly, comprising a laser beam generator (1), a laser scanner (2), a linear or matrix-like first sensor arrangement (3.1-3.n) of first individual sensors (3.1) with a same first sensitivity, and at least one linear or matrix-like second sensor arrangement (4) of second individual sensors (4.1-4.n) which is displaced to the first sensor arrangement (3) of the first individual sensors (3.1-3.n), the second individual sensors (4.1-4.n) having a same second sensitivity which is different from the first sensitivity.

Description

Technical Field

[0001] The present invention relates to an apparatus for ablating material to a predetermined wall thickness by scanning a processing laser beam on a vehicle assembly along a predetermined fracture line. Background Technology

[0002] It is well known that lasers are used to create predetermined break lines in vehicle components, such as for airbag openings in dashboards, door panels, or steering wheel hubs, or for break points in passenger compartment protrusions, such as cup holders. These predetermined break lines must reliably break when necessary while also meeting aesthetic requirements for the component's appearance; that is, the predetermined break should not be visible to the naked eye of vehicle occupants. Therefore, during their creation, sensors control the peeling of material along the predetermined break line surrounding the predetermined break. Similarly, in other applications, such as in the packaging industry, predetermined break lines are known to be introduced into containers as a separation aid. To create predetermined break lines by peeling material using lasers, incompletely severed slits, openings, or micropores are introduced into the relevant workpiece, penetrating only through extremely small holes. Sensor monitoring allows for the generation of reproducible residual wall thickness or micropores invisible to the naked eye along the predetermined break line; that is, when radiation energy penetrating the residual wall or micropore is detected, a preset threshold is used as a control variable. For this purpose, at least one individual sensor is arranged on the workpiece side (visible side) opposite the laser. If the workpiece has only a certain excess wall thickness or micro-hole (hereinafter referred to as excess wall thickness) within a predetermined fracture line at the corresponding machining location, the sensor detects the transmitted portion of the machining laser radiation during machining. The relative motion required to create the predetermined fracture line by energy radiation can be generated by either the laser beam as a tool or by the workpiece (here, the assembly). As the laser beam moves, either the individual sensors move synchronously, or the individual sensors are arranged along the predetermined fracture line such that each possible machining location along the predetermined fracture line is within the field of view of at least one individual sensor.

[0003] When individual sensors are synchronously driven, the identical signals generated by them are a measure of the same wall thickness.

[0004] In an arrangement of individual sensors, they are matched in sensitivity so that, under the same transmitted radiation, the individual signals generated by the received individual sensors produce the same resulting signal, a measure of the same wall thickness. In this case, sensitivity should be understood as dynamic range and resolution within that dynamic range, as well as the spectral range and spectral resolution of the corresponding individual sensor. Individual sensors have different sensitivities, especially when they transmit signals in different spectral ranges and / or different dynamic ranges.

[0005] Whether the predetermined break line is formed by a generalized circular hole or by an extended slit with a bridging section of varying length and a wall thickness of varying (or even zero) size, the design depends on the material properties of the assembly, creating a predetermined break line that can be opened by a predetermined, defined tearing force. Depending on the material selection, this may be applied to a variety of different wall thicknesses.

[0006] For the purposes of this specification, "transmitted radiation" should be understood as the processing laser radiation that passes through the material at the processing location, as well as the radiation that occurs at the processing location through the interaction between the processing laser radiation and the material. Identical transmitted radiation is radiation with the same spectral components and the same intensity.

[0007] The known differences in sensor design among existing devices lie in the presence of individual sensors, linear arrangements of individual sensors, or arrays of individual sensors. All individual sensors have the same sensitivity, which is specified in the device design based on the material properties of the assembly. Adaptation of existing devices to the transmitted radiation of an anticipated impact can be achieved, as appropriate, through electronic variations in the sensitivity of individual sensors or through upstream connected filters.

[0008] As stated above, for the purposes of this application, sensitivity encompasses dynamic range and resolution within that dynamic range, as well as the spectral range and spectral resolution of the corresponding individual sensor. Individual sensors possess different sensitivities, particularly when they transmit signals across different spectral ranges and / or different dynamic ranges. Summary of the Invention

[0009] The purpose of this invention is to provide a device that can be flexibly used for various materials in vehicle assembly parts without requiring separate adjustments.

[0010] To achieve the above objectives, the present invention provides a universal apparatus for creating predetermined break lines in vehicle assemblies, comprising a laser beam generator, a laser scanner, and a linear or matrix-shaped first sensor device having first individual sensors with the same first sensitivity and the same opening angle. The first sensor device is arranged within the scanning area of ​​the laser scanner, and adjacent first individual sensors have equidistant and overlapping fields of view. A linear or matrix-shaped second sensor device with at least one identical second individual sensor is present, offset relative to the first sensor device within the scanning area of ​​the laser scanner, and the second individual sensor has the same second sensitivity, which differs from the first sensitivity. Advantageously, the first and second individual sensors have paired overlapping fields of view.

[0011] Advantageously, the different sensitivities of the first and second individual sensors may involve different dynamic ranges.

[0012] Alternatively or additionally, the different sensitivities of the first and second monomer sensors involve different spectral ranges and / or different resolutions.

[0013] Preferably, there is exactly one first sensor device and exactly one second sensor device, or there are a first sensor device, a second sensor device and a third sensor device. Attached Figure Description

[0014] Exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. In the drawings:

[0015] Figure 1 A schematic diagram of a device according to the prior art is shown, including a first sensor device and signals generated at two different processing locations;

[0016] Figure 2 A schematic diagram of the device according to the invention is shown, including a first sensor device and a second sensor device, as well as signals generated at two different processing locations;

[0017] Figure 3 It shows the use of two moments Figure 2 The diagram shows the equipment performing processing at the processing location and the signals generated by a pair of sensors at these two moments;

[0018] Figure 4 The diagram illustrates the processing at a processing location using a device comprising a first sensor device, a second sensor device, and a third sensor device at two different times, and the signals generated by the sensor triplets at these two times. Detailed Implementation

[0019] Figure 2 The diagram schematically illustrates an exemplary embodiment of a device according to the present invention for creating a predetermined break line in an assembly of a vehicle. As is known in practice with prior art devices, such as... Figure 1 As schematically shown, it includes a laser generator 1, a laser scanner 2, and a first sensor device 3 having a large number of first individual sensors 3.1-3.n. The first sensor device 3 can be arranged in a linear or matrix configuration.

[0020] The linear configuration of the first sensor device 3 requires fewer first single sensors 3.1-3.n, but relates to the specific line layout and position of the predetermined break line within the additional components.

[0021] On the other hand, compared with the linear configuration, the matrix configuration of the first sensor device 3 requires several times more first individual sensors 3.1-3.n, but it can be flexibly applied to create predetermined break lines in different assembly positions or different line layouts.

[0022] In this way, for the same residual wall thickness at each processing location along the predetermined fracture line caused by transmitted radiation, the same result signal is formed. Regardless of whether the first sensor device 3 is linear or matrix-shaped, the first individual sensors 3.1-3.n are arranged at equal distances from their respective adjacent first individual sensors 3.1-3.n, have the same subtraction angle α, and have the same sensitivity.

[0023] The size of the angle α is sufficient to allow transmitted radiation at each machining location to be detected by multiple first-unit sensors 3.1-3.n. The individual signals generated by the first-unit sensors 3.1-3.n produce a result signal as a measure of the intensity of transmitted radiation at the machining location. The excess wall thickness of the machining location can be derived from the transmission characteristics of the additional component material or based on a previously determined comparison value related to the excess wall thickness.

[0024] The first sensor device 3 is arranged within the scanning range of the laser scanner 2, such that the processing laser beam emitted by the laser generator is distributed to multiple first individual sensors 3.1-3.n at each scanning position, meaning that transmitted radiation from the processing area can be detected by multiple first individual sensors 3.1-3.n. In this respect, the device according to the invention is no different from the device according to the prior art.

[0025] The basic technical feature of the present invention is that there is at least one linear or matrix-shaped second sensor device 4 of the same type as the first sensor device 3, the second sensor device 4 is offset relative to the first sensor device 3, and the second sensor device 4 includes second individual sensors 4.1-4.n with the same second sensitivity as each other, the second sensitivity being different from the first sensitivity of the first individual sensors 3.1-3.n.

[0026] Advantageously, the first single-unit sensor 3.1-3.n and the second single-unit sensor 4.1-4.n each form a pair of sensors, their field of view A 3.1-4.n Nearly completely overlapping.

[0027] In reality, these two sensors will not have completely overlapping fields of view A. 3.1-4.nBecause they cannot be arranged in the same position. Since the first single-unit sensors 3.1-3.n and the second single-unit sensors 4.1-4.n not only have the same opening angle α, but also a larger opening angle α, and are arranged in pairs as close to each other as possible, the field of view A of the first single-unit sensors 3.1-3.n and the second single-unit sensors 4.1-4n forming a corresponding pair of sensors is... 3.1-4.n The overlap is so great that they can be considered as coincident, and thus as completely overlapping fields of view A. 3.1-4.n .

[0028] Figure 3 The diagram illustrates the processing at the same processing location at different times t1 and t2. The sensitivity difference here is primarily due to the different dynamic ranges of the first individual sensor 3.1-3.n and the second individual sensor 4.1-4.n. If the intensity of the transmitted radiation is low, only the first individual sensor 3.1-3.n (only one shown in this figure) responds at the first time t1 after only a few scan runs. However, if the intensity of the transmitted radiation is higher, both the first individual sensor 3.1-3.n and the second individual sensor 4.1-4.n (only one shown in this figure) are covered at the second time t2 after multiple scan runs to provide a signal related to the intensity of the transmitted radiation.

[0029] The dynamic range of the first individual sensor 3.1-3.n and the second individual sensor 4.1-4.n, as well as their overlap, can be advantageously selected such that the first individual sensor 3.1-3.n and the second individual sensor 4.1-4.n form a result signal as a measure of achieving a specific wall thickness. Advantageously, the resolution can also be different in different dynamic ranges, wherein the second individual sensor 4.1-4.n has lower sensitivity but higher resolution than the first individual sensor 3.1-3.n.

[0030] In summary, a larger dynamic range can be used to create predetermined break lines. The sensitivity shown in the figure is merely illustrative.

[0031] The resulting greater dynamic range can also be used to etch to different wall thicknesses at different locations along a predetermined fracture line. Alternatively, if the first monomer sensor 3.1-3.n or the second monomer sensor 4.1-4.n is used for detection, etching can be performed according to different processing schemes.

[0032] The device, using two sensor devices 3 and 4, can also be used to process different assemblies that exhibit significantly different transmission behaviors to the laser radiation. For example, if the transmitted radiation intensity detected by the first individual sensor 3.1-3.n is very low, the processing plan can be changed; conversely, if the transmitted radiation intensity detected by the second individual sensor 4.1-4.n is relatively high, processing can be terminated. It can also process assemblies that are identical in nature but exhibit significantly different transmission behaviors between batches, such as when the leather color differs, because the sum of the two dynamic ranges results in a larger dynamic range.

[0033] Note that the first individual sensor 3.1-3.n and the second individual sensor 4.1-4.n are chosen so that their spectral ranges are different. The first individual sensor 3.1-3.n is more sensitive to the spectrum of the processing laser radiation, while the second individual sensor 4.1-4.n is more sensitive to the spectrum of radiation generated at the processing site due to the interaction between the processing laser radiation and the material, and vice versa.

[0034] The first and second sensitivities can also vary in different combinations of dynamic ranges and spectral ranges.

[0035] Figure 4 The diagram illustrates the signals of a first individual sensor 3.1, a second individual sensor 4.1, and a third individual sensor 5.1 at two times t1 and t2, according to another exemplary embodiment. In this exemplary embodiment, the device further includes a third sensor unit 5, which has third individual sensors 5.1-5.n. This figure shows one individual sensor from each sensor unit, similar to the exemplary embodiment with a pair of sensors described above, forming a sensor triplet.

[0036] Advantageously, the third sensitivity of the third individual sensor 5.1-5.n, belonging to the sensor ternary group, is determined such that when a safety threshold is reached, the resulting signal formed by the signal from the third individual sensor 5.1-5.n indicates that the required residual wall thickness has not yet been reached, thus displaying an error message. This means that although a specific resulting signal formed by the signal from the second individual sensor 3.1-3.n indicates that the required residual wall thickness has been reached, the first resulting signal formed by the signal from the third individual sensor 5.1-5.n already indicates that the predetermined break line no longer meets the requirements.

[0037] Furthermore, the above-described feasible solution for a device having only a first single-unit sensor 3.1-3.n and a second single-unit sensor 4.1-4.n can also be transferred to a device having an additional third single-unit sensor 5.1-5.n.

[0038] If the device has multiple identical sensor units, each of which detects transmitted radiation at the processing location along a predetermined fracture line using multiple individual sensors, and the individual sensors of different sensor units have different sensitivities, then the sensitivity range is expanded to a wider spectral and / or dynamic range compared to devices according to the prior art.

[0039] List of reference numerals

[0040] 1. Laser beam generator

[0041] 2. Laser scanner

[0042] 3 First sensor device

[0043] 3.1-3.n First individual sensor

[0044] 4. Second sensor device

[0045] 4.1-4.n Second Single-Unit Sensor

[0046] 5. Third sensor device

[0047] 5.1-5.n Third individual sensor

[0048] α angle

[0049] A 3.1-4.n Field of view

[0050] t1 First Moment

[0051] t2 Second Time

Claims

1. A universal apparatus for creating predetermined break lines in vehicle assemblies, comprising a laser beam generator (1), a laser scanner (2), and a linear or matrix-shaped first sensor device (3), wherein the first sensor device (3) has first individual sensors (3.1-3.n) with the same first sensitivity and the same opening angle (α), wherein, The first sensor device (3) is arranged within the scanning area of ​​the laser scanner (2), and the adjacent first individual sensors (3.1-3.n) have equal distances and overlapping fields of view (A) with each other. 3.1-4.n ), Its features are, A linear or matrix-shaped second sensor device (4) with at least one identical second single sensor (4.1-4.n) is provided, the second sensor device (4) being offset relative to the first sensor device (3) within the scanning area of ​​the laser scanner (2), and the second single sensor (4.1-4.n) having the same second sensitivity, which is different from the first sensitivity.

2. The universal apparatus for creating a predetermined break line in a vehicle assembly according to claim 1, characterized in that, The first single-unit sensor (3.1-3.n) and the second single-unit sensor (4.1-4.n) have overlapping fields of view (A) in pairs. 3.1-4.n ).

3. The universal apparatus for creating a predetermined break line in a vehicle assembly according to claim 1 or 2, characterized in that, The different sensitivities of the first individual sensor (3.1-3.n) and the second individual sensor (4.1-4.n) involve different dynamic ranges.

4. The universal apparatus for creating a predetermined break line in a vehicle assembly according to claim 1 or 2, characterized in that, The different sensitivities of the first monomer sensor (3.1-3.n) and the second monomer sensor (4.1-4.n) involve different spectral ranges.

5. The universal apparatus for creating a predetermined break line in a vehicle assembly according to claim 3, characterized in that, The different sensitivities also involve different resolutions.

6. The universal apparatus for creating a predetermined break line in a vehicle assembly according to claim 3, characterized in that, There is exactly one first sensor device (3) and exactly one second sensor device (4).

7. The universal apparatus for creating a predetermined break line in a vehicle assembly according to claim 2, characterized in that, There are a first sensor device (3), a second sensor device (4) and a third sensor device (5).

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