Manufacturing system and method for manufacturing component
Through a self-regulated manufacturing system, the use of additive manufacturing and data analysis technology, the problems of long development cycles and low production flexibility of traditional vehicles are solved, and an efficient and flexible vehicle component production process is achieved.
Patent Information
- Application Number
- CN202380042891.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2022-10-18
- Filing Date
- 2023-10-09
- Publication Date
- 2025-02-07
AI Technical Summary
Traditional vehicles have long development cycles and material diversity lead to complex jointing methods, resulting in production planning and low flexibility.
Design a self-regulated manufacturing system, use production equipment to perform the additive manufacturing process, collect and analyze on-site data through data acquisition and processing equipment, generate optimized process target data and development data, and realize a self-optimized production process.
Achieve high change flexibility, shorten development and manufacturing cycles, reduce trial production steps, and directly transition from prototype manufacturing to mass production, saving time and reducing costs.
Smart Images
Figure CN119404161A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to a production system for producing a component, in particular a vehicle component, and a method for producing a component, in particular a vehicle component. Background Art
[0002] Conventional vehicle development is accompanied by long development and maintenance cycles. The small-part and multi-material body leads to a high degree of complexity in the joining methods and to complex production planning. As a result, existing automobile production has only low flexibility with regard to changes. Summary of the invention
[0003] Against this background, the object of the present invention is to provide a possibility for improving the production of components. In particular, a possibility for achieving high flexibility in changes should be specified. On the other hand, a possibility for accelerating the development and production of automotive components should be provided.
[0004] This object is achieved by a production system for producing a component according to claim 1 and a method according to claim 10. Further advantageous embodiments are apparent from the dependent claims and the following description.
[0005] A manufacturing system is proposed, which is used to manufacture a component using a production device, which is designed to perform an additive manufacturing process. In the additive manufacturing process, the component is manufactured according to process target data. The manufacturing system includes at least one data acquisition device, which is designed to acquire field data, which characterizes the manufactured component and / or the manufacturing process performed. The data acquisition device can, for example, have a sensor or an inspection device for acquiring field data. The data acquisition device can also have a data memory, in which the field data is stored.
[0006] In addition, the manufacturing system has at least one data processing device, which is designed to analyze the field data and to generate optimized development data and / or optimized process target data when using the field data. The data processing device can include, for example, a computing unit or a computer, on which suitable software for analyzing and generating the desired data runs.
[0007] According to the invention, the manufacturing system is designed to be self-regulating, whereby the optimized process target data are used to manufacture further components by the production device. The optimized process target data are transmitted to the production device, for example as new process target data, and used as a basis for further additive manufacturing methods. The production device, the data acquisition device and the data processing device are preferably in a data connection (wired or wireless) in order to enable data exchange.
[0008] The invention is based on the idea of eliminating the process-related and data-technical separation / decoupling of development and production that has existed so far and instead linking them to one another in a self-regulating manner. In this context, the term "self-regulation" is understood in particular as the function of a control loop. Field data are fed back into the control loop and influence the design data or the process target data generated thereby. This provides a self-optimizing system that already evaluates the components during their production, feeds the findings back into the development process and uses them to improve the components or the production process. With such a system, pilot production can be dispensed with. Prototype production can be carried out directly in the context of subsequent series production and can be transitioned to series production almost seamlessly. This results in a significant potential for saving time and reducing costs.
[0009] In a preferred design, the manufacturing system further comprises a digital data platform, on which at least the optimized development data, the optimized process target data and the field data are stored. Centralized access can be achieved by bundling all relevant data on a common data platform. This can achieve high data transparency and can help further accelerate the development and production processes if all relevant parameters and data can be quickly obtained.
[0010] In one embodiment, it is particularly preferred that the data platform is cloud-based. This makes it possible to access relevant data from different development and / or production sites worldwide. This also enables improved collaboration across large distances. In particular, the cloud-based data platform can be used as a global blueprint for future production centers.
[0011] Development data include data for developing a component or generated within the scope of a development process. In particular, design data (e.g. CAD data), data from product and material databases, quality data, design-specific data, construction space data and / or requirement data are stored as development data. Optimized development data are development data that have been revised and, if necessary, modified based on field data. This optimization can be performed, for example, with the aid of a database in which a large amount of development data is stored.
[0012] Based on the development data, process target data are generated. The process target data specify the parameters that are necessary for operating a production system for producing components in terms of process technology. Here, material application rates, application speeds or process temperatures are listed purely as examples. Optimized process target data are process target data that have been revised and, if necessary, modified based on field data. For example, the optimization can be achieved by selecting process target data from a database that has a large amount of process data.
[0013] Field data include data that are obtained from already manufactured components and that describe the components qualitatively and / or quantitatively. This may be, for example, quality data that allow an assessment of the quality of the manufactured components. In addition, field data may include manufacturing process technology data that qualitatively and / or quantitatively describe the manufacturing process and / or reprocessing process that was performed.
[0014] For rapid and continuous product optimization, it is particularly advantageous, in one embodiment, to use a self-learning artificial intelligence to generate the optimized development data and / or the optimized process data. The self-learning artificial intelligence may include, for example, an artificial neural network, which analyzes field data and generates optimized process data or optimized development data. The artificial neural network may include, for example, a computing unit and a memory that simulates a neuron model.
[0015] For the production of large components and / or large component groups, it is particularly advantageous to arrange a plurality of production plants in a common production cell. Within the production cell, the production plants preferably jointly produce a component or a component group. In such a production cell, the individual production plants can cooperate and work with one another and, for example, be interconnected in terms of data technology and / or control technology.
[0016] In the additive manufacturing process performed by the production equipment, basically any known additive manufacturing method can be involved. These methods include, for example, laser sintering, laser beam melting or 3D printing. With the help of these methods, components can be constructed generatively. Here, the additive manufacturing method provides high flexibility in terms of component geometry. However, it is particularly preferred that the production equipment is designed to perform an additive manufacturing method based on wire. Accordingly, the additive manufacturing process can include an additive manufacturing method based on wire. Here, the wire material is melted using an arc or a high energy source (such as a laser) and deposited layer by layer in the desired shape with the help of a multi-axis manipulator to produce components. WAAM (Wire Arc Additive Manufacturing) or laser DED (Laser Direct Energy Deposition-Verfahren (Laser Directed Energy Deposition Method)) are listed here as examples. The additive manufacturing method based on wire is outstanding in terms of very high coating speed and high flexibility in terms of the geometry that can be coated. In addition, when using corresponding wire materials, it is possible to use the method to construct components with very high ductility.
[0017] In addition, a method for manufacturing a component, in particular a vehicle component, is proposed, wherein the component is manufactured in an additive manufacturing process by means of a production device in a manufacturing system according to process target data. In the method, field data characterizing the manufactured component and / or the manufacturing process performed are collected. The field data are analyzed and processed by at least one data processing device, and optimized process target data and, if necessary, optimized development data are generated while using the field data. The optimized process target data are then used to manufacture other components by means of the production device. By generating optimized process target data and importing them back into the method, the entire production process is designed as a self-regulating and self-optimizing method. Preferably, the method is performed using a manufacturing system as described above, and the same technical effects and advantages as those already described for the manufacturing system are achieved here. The features and details described in conjunction with the manufacturing system are also applicable in conjunction with the method according to the invention, and vice versa accordingly, so that the disclosures for each aspect of the invention are always referenced or can be referenced to each other.
[0018] In order to be able to realize and implement component changes as quickly as possible, in one embodiment, optimized development data and / or optimized process target data are preferably generated within a production cycle. Thus, component changes can be quickly initiated and implemented almost overnight.
[0019] A wide variety of components can be produced using the production system. Due to the flexible production of even highly complex components and the short change times, the method is particularly suitable for the production of vehicle components, in particular structural components of vehicle bodies or chassis components.
[0020] Further advantages, features and details of the invention are apparent from the following description, in which exemplary embodiments of the invention are described in detail with reference to the accompanying drawings. The features mentioned in the claims and the description may be essential to the invention individually or in any combination. If the term "may" is used in this application, this refers to both technical possibilities and actual technical implementation. BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The following describes the embodiments according to the accompanying drawings.
[0022] Figure 1 A flowchart for illustrating an exemplary manufacturing system and method is schematically shown, and
[0023] Figure 2 Another diagram is shown schematically to illustrate an exemplary production system. DETAILED DESCRIPTION
[0024] Figure 1A flow chart is shown for describing a process in an exemplary manufacturing system and in an exemplary method. Based on development data E, process target data P are generated by at least one data processing device 30. Based on these process target data P, a component (exemplarily a vehicle component) is produced in an additive manufacturing process by means of a production device 10 in the manufacturing system 1. For example, based on Figure 1 , the three production devices 10 are arranged in a common production cell 12. The production system 1 can have more than one production cell with a varying number of production devices 10.
[0025] The manufacturing system 1 also has at least one data acquisition device 20, which is designed to acquire field data F, which characterize the manufactured components and / or the performed manufacturing processes. The field data are preferably quality data of the manufactured components and manufacturing process-technical data of the performed manufacturing processes. Alternatively or additionally, the field data can also be data acquired within the scope of the further processing process 50.
[0026] The field data F are fed back to the data processing device 30 and analyzed, and optimized process target data P' and, if necessary, optimized development data E' are generated using the field data F. If optimized development data E' are generated, they also flow into the optimization of the process target data. The optimization of the development data or process target data is preferably realized by means of a self-learning artificial intelligence running on the data processing device 30, for example.
[0027] Based on the current optimized process target data P', further (vehicle) components are produced by means of the production device 10. Field data F' are again acquired by means of the data acquisition device 20, which are fed back to the data processing device 30 and used to create further optimized process target data P' and, if necessary, further optimized development data E'. The production system 1 is thus designed to be self-regulating and thus self-optimizing for component production.
[0028] The manufacturing system 1 further has a data platform 40, on which at least the optimized development data E', the optimized process target data P' and the field data F are stored. In addition, the original development data E and the original process target data P may be stored on the data platform 40. The data platform 40 is preferably configured as a cloud-based data platform.
[0029] Figure 2Another diagram is shown for explaining an exemplary manufacturing system 1 and method. Development data E are collected and used via a data interface DS with the aid of artificial intelligence K1 to generate process target data P. For example, data E1 from a product and material database, data E2 based on empirical values from production, quality data E3, data E4 based on a belly space model, requirements E5 from a database, data E6 based on design requirements and / or structural data E7 flow into the development data E.
[0030] The components are produced in an additive manufacturing method using production devices 10 according to process target data P. A plurality of production devices 10 are arranged, for example, in a common production cell 12. The production devices are preferably interconnected so that the communication of the production components is part of the production system 1.
[0031] During and after the production of the (vehicle) component, field data F are collected and transmitted to the data interface DS. For example, process data F1, data F2 based on post-processing (e.g. micro-processing or macro-processing) in the process, data F3 based on post-processing after the actual manufacturing process and / or quality data F4 of the component are collected as field data F. These field data are, for example, introduced back into the manufacturing system via the data interface DS. The artificial intelligence K1 then creates optimized process target data and / or optimized development data based on the field data, which in turn serve as the basis for manufacturing new components.
[0032] Such a production system 1 can be arbitrarily scaled to form a production system (indicated by dashed lines) with more production devices 10 or more production cells 12 , thereby ensuring flexible adaptation to changing production requirements.
[0033] Reference numerals list
[0034] 1 Manufacturing System
[0035] 10. Production Equipment
[0036] 12 Manufacturing Units
[0037] 20 Data acquisition equipment
[0038] 30 Data processing equipment
[0039] 40 Data Platform
[0040] 50 Reprocessing
[0041] E, E', E1-E7 development data
[0042] F, F1-F4 Field Data
[0043] DS Data Interface
[0044] Kl Artificial Intelligence
[0045] P, P' process target data
Claims
1. A manufacturing system (1) for manufacturing a component, the manufacturing system comprising: A production device (10) designed to carry out an additive manufacturing process for producing a component according to process target data (P, P'); at least one data acquisition device (20) designed to acquire field data (F) characterizing the manufactured component and / or the performed manufacturing process; at least one data processing device (30) which is designed to evaluate the field data (F) and to generate optimized development data (E') and / or optimized process target data (P') using the field data (F), The production system (1) is designed to be self-regulating, whereby the optimized process target data (P') are used to produce further components by means of the production facility (10).
2. The manufacturing system according to claim 1, wherein: The manufacturing system also has a digital data platform (40), on which at least the optimized development data (E'), the optimized process target data (P') and the field data (F) are stored.
3. The manufacturing system according to claim 2, wherein: The data platform (40) is cloud-based.
4. The manufacturing system according to claim 2 or 3, wherein: Design data, data from a product database and a material database, quality data, design-specific data, construction space data and / or requirement data are stored as development data (E) on the digital data platform (40).
5. The manufacturing system according to any one of the preceding claims 2 to 4, wherein: Quality data of the manufactured components and manufacturing process-related data of the performed manufacturing and / or further processing processes (50) are recorded as field data (F).
6. A manufacturing system according to any one of the preceding claims, wherein: A self-learning artificial intelligence is used to generate the optimized development data (E′) and / or the optimized process data (P′).
7. A manufacturing system according to any one of the preceding claims, wherein: A plurality of production plants (10) are arranged in a common manufacturing unit (12).
8. A manufacturing system according to any one of the preceding claims, wherein: The production device (10) is designed to carry out a wire-based additive manufacturing method.
9. A manufacturing system according to any one of the preceding claims, wherein: The production system is designed for producing a vehicle component.
10. A method for producing a component, wherein: According to the process target data (P, P'), a component is produced in an additive manufacturing process by means of a production device (10) in a manufacturing system (1), collecting field data (F) characterizing the manufactured component and / or the manufacturing process performed, The field data (F) are evaluated by at least one data processing device (30) and optimized development data (E') and / or optimized process target data (P') are generated using the field data (F). The optimized process target data (P') are used for producing further components using the production plant (10).
11. The method according to claim 10, wherein: The generation of optimized development data (E') and / or optimized process target data (P') is performed within one production cycle.
12. The method according to claim 10 or 11, wherein: The additive manufacturing process includes a wire-based additive manufacturing method.
13. The method according to any one of claims 10 to 12, wherein: A vehicle component is manufactured as a component.
14. The method according to any one of claims 10 to 13, wherein: The method is performed using a production system ( 1 ) according to one of claims 1 to 9 .