Automated small-batch production of pressed parts

Abstract

The invention relates to a method for producing a small series of pressed parts, comprising the steps: - Providing (S1) a large number of circuit boards, and, in a first manufacturing pass, for each of the circuit boards in the following sequence: - Drawing or forming (S2) of a respective circuit board in a first individual press (1), - Cutting (S3) of the respective circuit board, semi-finished product or pressed part in a 3D laser cutting device (5), - Forming or bending (S5) a respective blank, semi-finished product or pressed part in a second individual press (3) and - Output (S6) of the respective finished pressed part, characterized by the fact that the respective finished pressed part is processed in a second manufacturing run in the same first single press (1) and in the same 3D laser cutting device (5), and in the same second single press (3), wherein the respective finished pressed part of the first run takes the role of the respective circuit board in the second run.

Description

[0001] The invention relates to a method for producing a small series of pressed parts, as well as a manufacturing plant for the fully automatic production of a small series of pressed parts.

[0002] In contrast to production lines for the mass automotive market, manufacturers of vehicles in the luxury segment or special sports cars, for example, may need to produce small series of components for vehicles.

[0003] Sheet metal components, in particular, are typically manufactured from raw blanks, which are first cleaned and oiled, by cutting and / or forming in several steps. Large presses designed for high-volume production are typically used for this purpose. Laser cutting is also known in the state of the art for processing sheet metal components.

[0004] CN 114952037 A relates to a laser cutting device for trimming the outer contour of a thin plate, comprising a laser cutting machine which has a laser cutting table which is arranged symmetrically on two longitudinal sliding shafts on either side of the laser cutting table, two ends of which are each erected on the two longitudinal sliding shafts, and transverse sliding shafts, laser cutting heads which are connected to the transverse sliding shaft, are connected to the transverse sliding shaft and a first drive device for driving the transverse slide shaft for reciprocating movement on the longitudinal slide shaft and a second drive device which is connected to the laser cutting head and for driving the laser cutting head for reciprocating movement on the transverse slide shaft are provided;further comprising a plate handling device provided with a six-axis robot and having a plate adsorption arrangement at the end of the sixth axis of the six-axis robot, wherein the laser cutting table is located within the gripping radius of the plate handling device;

[0005] US 2013 / 0319066 A1 also relates to a method comprising providing metal from which metal parts are to be manufactured and providing a press. The press consists of a forming tool positioned in the press and a first cutting laser positioned in the press. The method further comprises passing the metal through the press and forming the plurality of metal parts in the metal within the press by simultaneously cutting at least one of the plurality of metal parts with a first cutting laser and forming at least a portion of the plurality of metal parts with a forming tool.

[0006] DE10 2007 009 705 B3 describes a processing device for producing and processing molded parts of different three-dimensional structures, in particular body parts of a motor vehicle, with a clamping tool for clamping a molded part and a processing tool for forming or machining the clamped molded part.

[0007] DE10 324 244 A1 describes a method for producing outer skin panel parts for vehicles. A three-dimensionally shaped series outer skin panel for a series-produced vehicle type is produced from a sheet metal sheet. Before installation in a body-in-white, a customized outer skin panel for a small-series or individual vehicle of the vehicle type is produced from the three-dimensionally shaped series outer skin panel.

[0008] Typically, press lines with four to six individual presses are used to manufacture pressed parts / finished parts in large-scale production for the automotive industry. This process requires significant investments in machinery and tools (four to six individual tools are required), as well as significant external setup times for changing tools for the next production run. While several individual presses used in series, especially large presses designed for high volumes, in conjunction with mechanical cutting machines for correspondingly high volumes of pressed parts, justify their costs and personnel expenditure, operating such large presses is no longer profitable for the production of pressed parts, especially semi-finished products, in small series.

[0009] The object of the invention is to create an automated, cost-effective and personnel-reduced production of pressed parts, thereby reducing the number of required tools and ensuring a highly flexible manufacturing process through the combination of a few presses and 3D laser cutting systems, which is suitable for small-series production with reduced external setup time.

[0010] The invention is based on the features of the independent claims. Advantageous developments and refinements are the subject of the dependent claims.

[0011] A first aspect of the invention relates to a method for producing a small series of pressed parts, comprising the steps: - Providing a plurality of circuit boards, and, in a first manufacturing run, for each of the circuit boards in the following order: - Drawing or forming of a respective blank in a first individual press, - Cutting the respective circuit board in a 3D laser cutting device, and - forming or bending a respective blank in a second individual press; and - Dispensing of the respective finished pressed part;

[0012] The process steps describe the manufacturing process for producing pressed parts from blanks. Blanks are primarily flat metallic semi-finished products, such as steel or aluminum sheets. The blanks or semi-finished products are suitable for use in the bodyshell construction of motor vehicles. Essentially, the only work steps involved are pressing, cutting, and pressing, which requires only two individual presses and a 3D laser cutting device, and no mechanical cutting devices or additional individual presses.

[0013] This allows the production of pressed parts (e.g., as finished parts) in exterior or interior vehicle skin quality with a reduced number of required tools and a reduced number of presses in which the tools for producing pressed parts are installed. The previously required tools with cutting operations are replaced by integrated 3D lasers. Cutting systems completely replaced.

[0014] Due to the process-related, rather longer processing times in the 3D laser cutting machines, this manufacturing process results in reduced system output compared to the conventional production process for pressed parts / finished parts using press lines with four to six individual presses. Therefore, the combination of one or two presses with 3D laser cutting machines is primarily suitable for the efficient production of smaller production runs with reduced system output. The production bottleneck caused by laser cutting is compensated for in the small-batch manufacturing machine concept by the use of several (two to four) 3D laser cutting systems. Within the preferably fully automated manufacturing process, surface cleaning of the pressed parts is also preferably integrated directly after 3D laser cutting.

[0015] Advantageous effects of the invention are that lower costs and lower personnel requirements are incurred for the production of pressed parts in small series, while the manufacturing flexibility for the pressed parts increases. Pressed parts can be manufactured in a first and single production run; if a second production run for the pressed parts is added after the first production run, semi-finished products can be manufactured; this can also be achieved by using double tools in the first and then single production run. Unlike conventional series production of pressed parts, no more than four, in particular six, individual presses are required; instead, only one or two individual presses are needed. The pressed part trimming is realized using the 3D laser cutting system integrated into the process.

[0016] The process eliminates mechanical cutting operations, including the associated tools, and increases flexibility in smaller batch sizes, while still enabling fully automated production of pressed parts and semi-finished products, at least in small batch sizes. The process not only enables flexible and cost-effective small-batch production of pressed parts and semi-finished products, but also provides full flexibility for design changes (e.g., for model updates) and general component modifications, since, for example, laser cutting can be programmed instead of having to make tool changes.

[0017] According to an advantageous embodiment, the respective finished pressed part is processed in a second production run in the same first individual press and / or in the same 3D laser cutting device, and / or in the same second individual press of the first production run, wherein the respective finished pressed part of the first run takes on the role of the respective blank in the second run.

[0018] According to an advantageous embodiment, the respective finished pressed part is processed in a second production run in the same first individual press, subsequently in the same 3D laser cutting device, and again subsequently in the same second individual press as in the first production run, wherein the respective finished pressed part of the first run takes on the role of the respective blank in the second run.

[0019] This supplements the manufacturing process with a second production run, in which the semi-finished products (pressed parts) from the first production run are transported and processed fully automatically using the same machine concept, so that the finished parts are finally stacked in a load carrier and ready for use. While the first production run produces the pressed parts from the raw parts, the blanks, in the second production run, the pressed parts from the first production run are used as the new raw parts to produce new pressed parts.

[0020] According to a further advantageous embodiment, modified pressing tools are used in the first individual press and / or in the second individual press, and / or a modified laser cutting program is used in the 3D laser cutting device.

[0021] According to a further advantageous embodiment, at least one of the first individual press and the second individual press is a drawing press.

[0022] According to a further advantageous embodiment, the first individual press, the 3D laser cutting device and the second individual press are linked as a fully automated production system in which the respective board is automatically conveyed to the next processing station and handled by a robot manipulator.

[0023] According to a further advantageous embodiment, the boards are unstacked, cleaned and oiled when they are provided.

[0024] According to a further advantageous embodiment, the method further comprises the step of carrying out after cutting: - Cleaning each circuit board with a sword brush.

[0025] Cleaning each blank with a sword brush is preferably carried out in a cleaning cell and is therefore fully automated. This allows the surface cleaning of the blanks to be advantageously performed within the fully automated production process immediately after cutting by the 3D laser cutting system during their process path for producing the pressed parts.

[0026] According to a further advantageous embodiment, two to four individual 3D laser cutting systems are used in the 3D laser cutting device.

[0027] Each of the 3D laser cutting systems is preferably designed to process specific sections of the blanks, semi-finished products or pressed parts and to make the corresponding cuts assigned to them.

[0028] According to a further advantageous embodiment, the cutting of the blanks, semi-finished products or pressed parts is carried out exclusively by the 3D laser cutting device.

[0029] In particular, no mechanical cutting is used. Multiple 3D laser cutting machines (the bottleneck of the production line) in particular eliminate the need for cutting operations with mechanical tools. Furthermore, no more than two individual presses are used.

[0030] A further aspect of the invention relates to a manufacturing plant for the fully automated production of a small series of pressed parts, comprising a first device for providing a plurality of blanks, a first individual press for drawing or forming a respective blank, a 3D laser cutting device for cutting the respective blanks, semi-finished products or pressed parts, and a second individual press for forming or bending a respective blank, semi-finished product or pressed part; as well as a second device for dispensing the respective finished pressed part; wherein no further individual presses are provided in the manufacturing plant and no mechanical cutting device for the blanks, semi-finished products or pressed parts is provided.

[0031] Advantages and preferred developments of the proposed manufacturing plant result from an analogous and analogous transfer of the statements made above in connection with the proposed method.

[0032] Further advantages, features, and details will become apparent from the following description, which – where appropriate with reference to the drawings – describes at least one embodiment in detail. Identical, similar, and / or functionally equivalent parts are provided with the same reference numerals.

[0033] They show: Fig. 1: A process for the mass production of pressed parts according to the state of the art. Fig. 2: A method for producing pressed parts in small series according to an embodiment of the invention. Fig. 3: A method for producing pressed parts in small series according to another embodiment of the invention. Fig. 4: A method for producing pressed parts in small series according to another embodiment of the invention. Fig. 5-7: The phases of production from blank to pressed part according to an embodiment of the invention.

[0034] Fig. Figure 1 shows a schematic, conventional process flow from the state of the art for the production of pressed parts. It shows a material flow diagram for pressed part production using the example of a production run from the blank to the finished part on a press line with six press stages / six individual presses or press stages. The individual steps are... - Z1: unstacking the boards; - Z2: Cleaning and oiling the circuit boards; - Z3: Drawing / forming in the first press (drawing press); - Z4: (Next stage) cutting / forming in second press; - Z5: (Next stage) cutting / forming in third press; - Z6: (Next stage) cutting / forming in fourth press; - Z7: (Next stage) forming / bending in fifth press; - Z8: (Next stage) forming / bending in sixth press; - Z9: Quality control of finished parts; - Z10: Stacking finished parts in load carriers;

[0035] Fig. 2 shows an exemplary method according to the invention for producing a small series of pressed parts with the aid of a material flow diagram based on a fully automated production system. This illustrates the production of pressed parts using the example of a production run from the blank to the finished part on a press line. In the first step, a large number of blanks are prepared S1 in an initial stack. The blanks are unstacked, cleaned, and oiled before being passed sequentially through the following production line: In a first individual press 1, the drawing or forming S2 of each blank takes place. A drawing press can be used for this purpose. The blanks are inserted into and removed from the machines, such as the first individual press 1, by robot manipulators 9. After the blanks have been pressed in the first individual press 1, they are conveyed to a 3D laser cutting device 5.The 3D laser cutting device 5 has two to four individual 3D laser cutting systems 7. The individual laser cutting systems 7 are operated by the robot manipulators 9, with two parallel lines being used to increase throughput. In each of the lines, two laser cutting systems 7 are provided sequentially for the blanks. There, 3D laser cutting S3 of the respective blanks, semi-finished products, or pressed parts takes place without using mechanical cutting. The cut blanks are then cleaned S4 with a sword brush. The blanks, semi-finished products, or pressed parts passing through the production line are then reassembled and formed or bent S5 in a second individual press 3. No further individual presses are required. Optionally, a quality control of the finished parts can now be performed, but can also be omitted, particularly if further processing steps are planned.Finally, the respective finished pressed part is discharged S6, whereby the semi-finished or finished parts are stacked in a load carrier.

[0036] Fig. 3 shows an extended manufacturing process, where all steps are carried out as described under Fig. 2 are initially carried out. However, after completion of the pressed parts according to step S6, they are additionally output in such a way that they are cut for further use in the 3D laser cutting device 5 and subsequently fed to the second individual press 3 to undergo quality control as finished pressed parts.

[0037] Fig. 4 shows another variant, which is similar to the variant with a second pass after Fig. 3 also uses the same machines. In contrast to Fig. 3, however, the pressed part obtained from the first pass is not fed directly to the 3D laser cutting device 5, but, analogous to the first pass, is also fed in the second pass first to the first individual press 1, then to the 3D laser cutting device 5, and finally to the second individual press 3.

[0038] In the multiple runs of the variants of the Fig. 3 and the Fig. 4, the same individual press 1, 3 and the same 3D laser cutting device 5 can be used with the same configuration or with a modified configuration. For example, a different tool can be inserted into the individual press 1, 3, or a new program can be executed in the 3D laser cutting device 5 to achieve refined or new cutting edges in the second pass.

[0039] Fig. 5 to Fig. Figure 7 shows an example of a blank that is cut and formed into a pressed part for a panel on the side wall of a motor vehicle in the process steps described above. Fig. 5 the board is shown as a raw part, is in Fig. 6 shows the programmed shape for laser cutting. In Fig. 7 shows the pressed part produced in the first pass of the above-mentioned process steps, after it was formed in a second individual press 3 after laser cutting. In Fig. 7, a mark is placed on the right edge to indicate an area intended for a further laser cutting pass.

[0040] Although the invention has been illustrated and explained in detail by preferred embodiments, the invention is not limited by the disclosed examples, and other variations may be derived therefrom by those skilled in the art without departing from the scope of the invention. It is therefore clear that a multitude of variations exist. It is also clear that the embodiments mentioned by way of example are truly only examples and should not be construed as limiting the scope, possible applications, or configuration of the invention in any way.Rather, the preceding description and the description of the figures enable the person skilled in the art to implement the exemplary embodiments in concrete terms, whereby the person skilled in the art, with knowledge of the disclosed inventive concept, can make various changes, for example with regard to the function or the arrangement of individual elements mentioned in an exemplary embodiment, without departing from the scope of protection defined by the claims and their legal equivalents, such as further explanations in the description. List of reference symbols 1 first single press 3 second single press 5 3D laser cutting device 7 3D laser cutting machines 9 robot manipulators S1 Provision S2 Drawing or forming S3 cutting S4 Cleaning S5 Forming or bending S6 Output Z1 destacking Z2 Cleaning and oiling Z3 Forming Z4 Forming Z5 Forming Z6 Forming Z7 Forming Z8 Forming Z9 Quality Control Z10 layers

Claims

[1] Method for producing a small series of pressed parts, comprising the steps: - Providing (S1) a plurality of circuit boards, and, in a first manufacturing run, for each of the circuit boards in the following order: - drawing or forming (S2) of a respective blank in a first individual press (1), - cutting (S3) the respective blanks, semi-finished products or pressed parts in a 3D laser cutting device (5), and - forming or bending (S5) a respective blank, semi-finished product or pressed part in a second individual press (3); and - Discharge (S6) of the blank or semi-finished product or the respective finished pressed part, characterized bythat the respective finished pressed part is processed in a second production run in the same first individual press (1) and in the same 3D laser cutting device (5), and in the same second individual press (3), wherein the respective finished pressed part of the first run takes on the role of the respective blank in the second run. [2] Method according to claim 1, wherein modified pressing tools are used in the first individual press (1) and / or in the second individual press (3), and / or a modified laser cutting program is used in the 3D laser cutting device (5). [3] Method according to one of the preceding claims, wherein at least one of the first individual press (1) and the second individual press (3) is a drawing press. [4] Method according to one of the preceding claims, wherein the first individual press (1), the 3D laser cutting device (5) and the second individual press (3) are linked as a fully automated production system in that the respective blank, semi-finished product or pressed part is automatically conveyed to the next processing station and handled by a robot manipulator (9). [5] Method according to one of the preceding claims, wherein the boards are unstacked, cleaned and oiled when they are provided. [6] Method according to one of the preceding claims, further comprising the step of performing after cutting: - Cleaning (S4) a respective circuit board, semi-finished product or pressed part with a sword brush. [7] Method according to one of the preceding claims, wherein two to four individual 3D laser cutting systems (7) are used in the 3D laser cutting device (5). [8] Method according to one of the preceding claims, wherein the cutting of the blanks, semi-finished products or pressed parts is carried out exclusively by the 3D laser cutting device (5). [9] A manufacturing plant for the fully automatic production of a small series of pressed parts for a method according to one of the preceding claims, comprising a first device for providing a plurality of blanks, a first individual press (1) for drawing or forming a respective blank, a 3D laser cutting device (5) for cutting the respective blank, semi-finished product or pressed part, and a second individual press (3) for forming or bending a respective blank, semi-finished product or pressed part; as well as a second device for dispensing the respective finished pressed part; wherein no further individual presses are provided in the manufacturing plant and no mechanical cutting device for the blanks is provided.

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