METHOD AND DEVICE FOR JOINING AND FORMING FLAT MATERIALS

Description

[0001] The present invention relates to a method for joining and forming flat materials and to a device for carrying out the method according to the preamble of claims 1 and 10 (see e.g. CN 204 818 435 U).

[0002] The process is used to produce profile elements which are composed of different flat materials, preferably with different physical and technical properties, and which are then subjected to a forming process after the flat materials have been joined or welded.

[0003] For the purposes of the invention, a profile element is preferably understood to be a strand-shaped body which, in its longitudinal direction, has at least a partially open contour on its circumference.

[0004] A particularly advantageous embodiment is one in which the flat materials are stored in supply devices, in particular a type of supply drawer, and these supply devices simultaneously serve as a flat material storage device. This use, previously unknown in the prior art, in which flat materials are removed from the supply device, only partially cut off, and the remaining pieces are returned to the supply device for a subsequent removal step, allows for a continuous flat material mix from different starting materials, which are combined in a freely selectable sequence through step-by-step removal and joining to form a hybrid component.

[0005] Special designs of components made of different flat materials, such as egProfiles with varying technical and physical properties of the flat materials can therefore be manufactured particularly efficiently.

[0006] The technical object of the present invention is to reduce energy and emissions, in particular through efficient production, as well as to save resources in construction profiles both during their production and during their use, as well as to simplify the production of such components overall.

[0007] The technical problem is solved by an object or a method having the technical features according to independent claims 1 and 10. Advantageous embodiments are the subject of the dependent claims, the description, and the drawings.

[0008] For the purposes of the invention, a composite workpiece is understood to be a workpiece composed of at least one first flat material joined to a second flat material. Furthermore, for the purposes of the invention, the number X is understood to be any desired number.

[0009] Furthermore, within the meaning of the invention, a first clamping device is understood to be an input-side clamping device, and a second clamping device is understood to be an output-side clamping device. Input-side and output-side are understood to mean that flat materials are fed in on the input side, and the processed flat materials are removed on the output side.

[0010] According to one aspect, the technical object of the invention is achieved by a method for joining and forming flat materials, wherein at least one first flat material and at least one second flat material are fed to a cutting-welding device in one supply device each assigned to the respective flat material, comprising the method steps: a) Providing the first flat material from a first supply device; b) Placing and clamping the first flat material on an input-side clamping device; c) Aligning the first flat material on a joining edge of an output workpiece, wherein the output workpiece is clamped on an output-side clamping device; d) Joining the first flat material to the output workpiece at the joining edge by means of a welding process to form a composite workpiece; e) Transporting the composite workpiece towards an output table by a first transport step; f) Separating a remaining piece of the first flat material from the composite workpiece at a separating edge; g) Removing, in particular retracting, the remaining piece of the first flat material from the input-side clamping device; h) Providing a second flat material from a second supply device;i) Placing and clamping the second flat material on an input-side clamping device; j) Aligning the second flat material at the separating edge on the composite workpiece, wherein the composite workpiece is clamped on an output-side clamping device; k) Joining the second flat material to the composite workpiece at the separating edge by means of a welding process; m) Repeatedly feeding the first flat material or the second flat material or further flat materials from respective supply devices.

[0011] This provides the technical advantage, for example, of using different flat materials to produce a customized composite workpiece that meets specific weight or stiffness requirements. This can be produced with multiple weld seams in a single cycle. This offers logistical advantages, for example, as the additional cycles otherwise required by a conventional welding machine can be eliminated. Furthermore, even very narrow flat material widths of approximately 10 mm can be processed into a composite workpiece, enabling fully optimized production of the composite workpiece in terms of cost, function, and weight.Furthermore, there are advantages in terms of environmental protection, as not only can energy and thus emissions be saved during the production of the composite workpieces, but the composite workpieces can also be specifically configured and used to save energy and weight. Furthermore, the generation of unnecessary scrap during production can be advantageously avoided, as process steps for removing material segments to reduce weight can be eliminated.

[0012] Furthermore, this provides the technical advantage that one of the flat materials can be quickly made available and used in the further course of the process.

[0013] In a further technically advantageous embodiment of the method, a method step a1) preceding method step a) is provided: a1) Carrying out an initial cut for edge preparation, wherein the first input material is trimmed and a first strip of the input material is separated as waste.

[0014] This provides the technical advantage, for example, of being able to produce a defined edge with a shape tailored to the requirements.

[0015] In a further technically advantageous embodiment of the method, a method step bi) following method step b) or i) is provided: bi) preparing, in particular trimming, an edge, wherein the preparation preferably takes place in the tensioned state.

[0016] This provides the technical advantage, for example, that the flat material can be trimmed precisely and the risk of distortion or slippage is minimized in order to enable the necessary tolerances to be met.

[0017] In a further technically advantageous embodiment of the method, it is provided that method step e) is carried out by means of the following method steps: e1) Release the input-side clamping device; e2) Move the composite workpiece clamped on the output-side clamping device by the first transport step using the output-side clamping device; e3) Clamp the input-side clamping device; e4) Release the output-side clamping device; e5) Move the output-side clamping device back e6) Clamp the composite workpiece using the output-side clamping device.

[0018] This provides the technical advantage, for example, of enabling the composite workpiece to advance, minimizing any potential slippage and, ideally, preventing it. This increases the precision and accuracy of joining the flat materials. For example, the distortion forces that occur during welding can be minimized by allowing the composite workpiece to remain in a clamped state at all times.

[0019] In a further technically advantageous embodiment of the method, the composite piece is clamped by means of the clamping device on the output side, particularly at the location of the last weld or joining edge. This achieves the technical advantage, for example, that the stresses and distortion forces occurring especially in the area of ​​the joining edge to be welded have a reduced influence on the alignment and thus the quality of a subsequent welding process.

[0020] In a further technically advantageous embodiment of the method, a method step l) following method step k) is provided: l) Repeating the preceding method steps with a number X of different flat materials.

[0021] This achieves the technical advantage, for example, that any dimensions of the composite workpiece are possible in at least one dimension and the composite workpiece can thus be manufactured to measure.

[0022] In a further technically advantageous embodiment of the method, a method step g1) following method step g) is provided: g1) Storage of the first flat material in a first provision device.

[0023] This provides the technical advantage, for example, that the first flat material can be reused later in the process and is quickly available. The remaining flat materials can also be made available in this way, enabling space-saving and rapid production. Furthermore, the cutting edge from the previous cutting process is already of the same quality as a trimmed edge, thus avoiding further trimming and the associated material loss.

[0024] In a further technically advantageous embodiment of the method, it is provided that the separation of method step f) takes place in a straight line or following a contour, wherein in particular the separation of method step f) takes place at an angle to the surface normal of the flat material.

[0025] This provides the technical advantage, for example, that the edge to be welded can be shaped as desired and individually and, in addition, it enables the use of advantages, such as those of a welding process using a V-cut.

[0026] In a further technically advantageous embodiment of the method, it is provided that a final method step comprises a forming process of the joined flat materials.

[0027] This achieves the technical advantage, for example, that the initially planar composite workpiece made from joined flat materials can be formed into a three-dimensional workpiece, offering additional properties and further application possibilities. For example, a composite workpiece formed into a support can be used in vehicle construction to reduce weight while maintaining stability, thus contributing to energy savings and emissions reduction.

[0028] A further embodiment of the method using a forming process provides that the forming process comprises bending with a bending angle, in particular between 45° and 135°, preferably approximately 90°, wherein by means of the method in particular a profile body open in its longitudinal direction is formed.

[0029] By applying the forming process as bending, an angled, particularly V-shaped or U-shaped open profile body can be produced in a simplified manner, which combines the advantages of the technical properties of the composite workpiece made of different joined flat materials

[0030] According to a further aspect, the technical object of the invention is achieved by a device for carrying out the method for joining and forming flat materials, comprising at least two supply devices, at least one first and at least one second clamping device, at least one cutting-welding device and at least one output table, wherein the supply devices are designed to be movable relative to the output table or relative to the second clamping device.

[0031] This provides the technical advantage, for example, that the flat materials can be fed into the process quickly and at any time, thus generating time and cost savings. For example, no additional space is required on the device itself for storing the flat materials, and the entire manufacturing process can be carried out on a single production line.

[0032] According to the invention, it is provided for the device that the supply devices are flat, in particular drawer-shaped and are designed with a feed adapted to the respective flat material for moving or retracting the flat materials.

[0033] In particular, the feed has freely programmable axes.

[0034] This provides the technical advantage, for example, that the individual flat materials can be placed against each other in any orientation for the joining process, or their orientation can be changed as desired, thus opening up further possibilities for customized production.

[0035] In a further technically advantageous embodiment of the device, each supply device comprises a first clamping device assigned to it, and the second clamping device is assigned to the output table. This achieves the technical advantage, for example, of minimizing the space required by the device and enabling a compact and space-saving manufacturing process.

[0036] In a further technically advantageous embodiment of the device, the supply devices are arranged vertically relative to one another. This achieves the technical advantage, for example, of minimizing the space required by the device and enabling a compact and space-saving manufacturing process.

[0037] In a further technically advantageous embodiment of the device, it is provided that the clamping devices comprise magnetic clamping technology, or vacuum clamping technology, or clamping bridge technology, wherein in particular the clamping devices are designed for clamping the flat materials on one side or on both sides.

[0038] This provides the technical advantage, for example, that any flat materials with any coating can be processed and the clamping of these flat materials can be optimized.

[0039] In a further technically advantageous embodiment of the device, it is provided that each supply device has clamping devices, in particular manipulators for aligning or locking the flat materials, wherein the clamping devices have in particular freely programmable axes of movement.

[0040] This provides the technical advantage, for example, that the flat materials can be moved three-dimensionally in space and joined together, which further improves the flexibility of customized production.

[0041] In a further technically advantageous embodiment of the device, it is provided that the cutting-welding device comprises at least one laser head, wherein the at least one laser head is designed for welding the flat materials, and / or for cutting the flat materials, and / or for weld seam preparation, in particular for carrying out an ablation step on the edge of the flat materials.

[0042] This provides the technical advantage, for example, of eliminating the need for additional fixtures for laser-assisted processing of flat materials, thus enabling space-saving and compact production. Furthermore, this saves time and energy during production, as additional laser or cutting equipment is no longer required.

[0043] In a further technically advantageous embodiment of the device, the cutting and welding device is designed as a laser portal, in particular as a 2D laser portal. This achieves the technical advantage, for example, of enabling improved cycle times during production in a single production line.

[0044] In a further technically advantageous embodiment of the device, the laser head is designed as a remote laser head or a near-field laser head. This achieves the technical advantage, for example, of increasing flexibility in the manufacturing process and allowing more complex structures to be processed and manufactured.

[0045] In a further technically advantageous embodiment of the device, the device comprises a conveyor for removing waste from the device, wherein the conveyor in particular comprises a collecting hopper and preferably comprises a suction device. This achieves the technical advantage, for example, that the device can be used in a compact and space-saving manner, and separated residues do not hinder the production process.

[0046] In a further technically advantageous embodiment of the device, the device comprises a transfer device between the output table and a forming device. This achieves the technical advantage, for example, of enabling rapid transport between these two positions, which can have a positive effect on production time.

[0047] In a further technically advantageous embodiment of the device, the flat materials are provided from a pre-material storage, in particular by means of flat material coils or flat material sheets. This achieves the technical advantage, for example, that the device can be operated continuously and downtimes, for example for refilling, can be avoided by independently loading the pre-material storage.

[0048] Embodiments of the invention are illustrated in the drawings and are described in more detail below. They show: Fig. 1: a schematic overview of a device for illustrating a method; Fig. 2: edge preparation by means of a trimming cut; Fig. 3: a separating cut for separating a first strip 4a from a flat material 4; Fig. 4: joining and welding a first flat material 4 to a second flat material 5; Fig. 5: release of an input-side clamping device 7 and advancement 50 of an output-side clamping device 8 for transporting a composite workpiece 20; Fig. 6: a separating cut for separating a strip 5a from a second flat material 5 after resetting the output-side clamping device 8; Fig. 7: repeating the steps for applying a strip of the third flat material 6 and repeating with any combination of the flat materials 4, 5, 6 to form a composite workpiece 20; and Fig 8: exemplary composite workpiece 20 as a combination of strips of flat materials 4, 5, 6.

[0049] A summary of the Figures 1 to 7 shows an exemplary embodiment of the method and a schematic representation of the device up to the production of the Figure 8 shown composite workpiece.

[0050] The supply devices 1, 2, 3 provide a flat material 4, 5, 6 which is assigned to them and lies on them, which can be clamped on an input-side clamping device 7 and an output-side clamping device 8, while it is processed with a cutting-welding device designed as a laser head 10 in order to be transported towards the output table 9. This is shown in Figure 1 with flat materials 4, 5, 6 that differ, for example, in their thickness. For example, flat materials with very different geometric or physical properties can be used advantageously.

[0051] The Figure 2shows that the first flat material 4 was displaced by means of the supply device 1 in the direction of the input-side clamping device 7 and partially beyond it in the direction of the output-side clamping device 8 and then undergoes a trimming cut by the laser head 10 for edge preparation. The strip of flat material 4 thus severed and not further designated can then be removed from the device as waste, which is not further illustrated.

[0052] As a result of the trimming cut, as in Figure 3 As shown, the first flat material 4 is again moved beyond the clamping device 7, and the output-side clamping device 8 now additionally clamps the first flat material 4. This advantageously enables the separating cut now performed by the laser 10 to produce a first strip of first flat material 4a to be carried out precisely and without distortion of the first flat material 4.

[0053] Once the first strip 4a has been separated, as shown in Figure 4 As shown, the now shortened first flat material 4c is withdrawn and stored for possible later use within the supply device. The first strip of the first flat material 4a remains clamped as the initial workpiece on the output-side clamping device. The supply devices then undergo a horizontal offset 40 in order to provide a second flat material 5. This flat material 5 is also initially trimmed upon its first use. This, like the first flat material 4, in the direction of the output-side clamping device and beyond the input-side clamping device and applied to the strip of the first flat material 4a still tensioned in the output-side clamping device 8. When the flat material 5 is applied to the flat material 4a, no further trimming takes place.

[0054] By means of a welding process now performed by the laser, the second flat material 5 is joined to the strip of first flat material 4a to form a composite workpiece 20, while both flat materials are always firmly clamped to the clamping devices 7, 8. The quality of the welding processes can thus be advantageously optimized if at least the first strip of first flat material 4a, or the composite workpiece 20, is at least partially firmly clamped at all times after separation, until the composite workpiece 20 is completely manufactured.

[0055] In Figure 5It is shown how the second flat material 5 joined to the first strip of first flat material 4a, released from the input-side clamping device 7, is pulled and moved by the output-side clamping device in the direction of the output table 9. Thus, the composite workpiece 20 formed at this time from the first strip of first flat material 4a and the second flat material 5 is displaced by a transport path 50 by means of a feed of the output-side clamping device so far that a further and in Figure 6 The separating cut shown can be made possible by means of the laser head 10.

[0056] In Figure 6It is shown that, as a result of the advance of the output-side clamping device 8, the composite workpiece 20 is first re-clamped by the input-side clamping device 7, the output-side clamping device 8 has been released, and this has been moved back to the input-side clamping device 7. Here, the output-side clamping device 8 again clamps the composite workpiece 20, and a precise separating cut of the laser head on the second flat material 5 is possible. This produces a second strip of second flat material 5a, which is now firmly welded to the first strip of first flat material 4a and together forms the composite workpiece 20 clamped on the output-side clamping device.

[0057] In Figure 7It is shown how the supply devices 1, 2, 3 are moved once again by an offset 40 in order to now provide a third flat material 6. This is joined and welded to the edge of the second strip of second flat material 5a using the laser head, analogous to the previous process.

[0058] By repeating the process steps, a composite workpiece 20 can be manufactured cost-effectively and quickly, which can be customized and individually tailored to reduce emissions during its production or use. The composite workpiece can be optimally adapted to desired requirements by combining flat materials that differ in their physical, geometric, or surface coating properties. A forming process can be used to form, for example, supports or components that exhibit customized properties in terms of weight or stability.

[0059] Figure 8 shows an exemplary composite workpiece as a combination of strips of flat materials. The flat materials 4, 5, 6 were processed using the described device and according to the described method into respective strips 4a, 4b, 5a, 5b, 6a, which were in turn joined together by means of weld seams 61. The composite workpiece 20 is then formed at the forming edges 60. Advantageously, for example, a tailor-made carrier can be produced which, due to its flat material mix, can be flexibly adapted to desired requirements. This can have a beneficial effect on reducing environmentally harmful emissions, as less scrap and waste is produced during production, production can be carried out quickly and energy-efficiently, and the formed composite workpiece 20 can be used to save weight, for example, in vehicle construction. List of reference symbols:

[0060] 1First supply device 2Second supply device 3Third supply device 4First flat material 4aFirst strip of first flat material 4bFifth strip of first flat material 4cRetracted, stored and shortened remnant of first flat material 5Second flat material 5aSecond strip of second flat material 5bFourth strip of second flat material 6Third flat material 6aThird strip of third flat material 7Input-side clamping device 8Output-side clamping device 9Output table 10Laser head 20Composite workpiece 40Offset of the supply devices 50Transport step distance / feed of the output-side clamping device 60Forming edges 61Weld seams

Claims

1. Method for joining and shaping flat materials (4, 5, 6), wherein at least one first flat material (4) and at least one second flat material (5) are fed to a cutting and welding device in respective supply devices (1, 2), each associated with one flat material (4, 5, 6), comprising the method steps of: a) supplying the first flat material (4) from a first supply device (1); b) placing and holding the first flat material (4) on an input-side holding device (7); the method characterized by the following steps: c) aligning the first flat material (4) at a joining edge of a starting workpiece, wherein the starting workpiece is held on an output-side holding device (8); d) connecting the first flat material (4) to the starting workpiece at the joining edge by means of a welding operation to give a composite workpiece (20); e) transporting the composite workpiece (20) in the direction of a delivery table (9) by a first transport step distance (50); f) separating a residual piece (4c) of the first flat material (4) from the composite workpiece (20) at a separating edge; g) removing, in particular withdrawing, the residual piece (4c) of the first flat material from the input-side holding device (7); h) supplying a second flat material (5) from a second supply device (2); i) placing and holding the second flat material (5) on an input-side holding device (7); j) aligning the second flat material (5) at the separating edge on the composite workpiece (20), wherein the composite workpiece (20) is held on an output-side holding device (8); k) connecting the second flat material (5) to the composite workpiece (20) at the separating edge by means of a welding operation; m) repeatedly feeding the first flat material (4) or the second flat material (5) or additional flat materials (6) from respective supply devices (1, 2).

2. Method according to Claim 1, comprising a method step that precedes method step a): a1) carrying out an initial cut for edge preparation, wherein the first input material (4) is trimmed, and a first strip of the input material is cut off as waste.

3. Method according to either of the preceding claims, comprising a method step that follows method step b) or i) : bi) preparing, in particular trimming, an edge, wherein preparation preferably takes place in the held state.

4. Method according to one of the preceding claims, characterized in that method step e) is carried out by means of the following method steps: e1) releasing the input-side holding device (7); e2) moving the composite workpiece (20), which is held on the output-side holding device (8), by the first transport step distance (50) by means of the output-side holding device (8); e3) applying the input-side holding device (7); e4) releasing the output-side holding device (8); e5) resetting the output-side holding device (8); e6) holding the composite workpiece (20) by means of the output-side holding device (8).

5. Method according to one of the preceding claims, characterized in that the composite workpiece (20) is held by means of the output-side holding device (8), in particular at the location of the last seam or joining edge formed.

6. Method according to one of the preceding claims, comprising a method step that follows method step k): l) repeating the preceding method steps with a number X of different flat materials.

7. Method according to one of the preceding claims, comprising a method step that follows method step g): g1) storing the first flat material (4) in a first supply device (1).

8. Method according to one of the preceding claims, characterized in that the process of separation in method step f) takes place in a straight line or following a contour, wherein, in particular, the process of separation in method step f) takes place at an angle to the surface normal of the flat material (4, 5, 6).

9. Method according to one of the preceding claims, characterized in that a concluding method step comprises a shaping process on the joined flat materials, wherein the shaping process preferably comprises edging with an edging angle, in particular between 45° and 135°, preferably about 90°, wherein, in particular, a profile body that is open in its longitudinal direction is formed by means of the method.

10. Device for carrying out a method for joining and shaping flat materials according to one of the preceding claims, comprising at least two supply devices (1, 2), at least one input-side and at least one output-side holding device (7, 8), at least one cutting and welding device, and at least one delivery table (9), characterized in that the supply devices (1, 2) are designed to be movable relative to the delivery table (9) or relative to the second holding device (2), wherein the supply devices (1, 2) are designed to be planar, in particular in the form of trays, and with a feed motion, matched to the respective flat material (4, 5, 6), for displacing or retracting the flat materials.

11. Device according to Claim 10, characterized in that the feed motion has freely programmable axes, and / or in that the supply devices (1, 2) are arranged vertically with respect to one another.

12. Device according to one of preceding Claims 10 or 11, characterized in that each supply device (1, 2) comprises a respectively associated first holding device (7), and the second holding device (8) is associated with the delivery table (9).

13. Device according to one of preceding Claims 10 to 12, characterized in that the holding devices (1, 2) comprise magnetic holding technology, or vacuum holding technology, or gripping yoke technology, wherein, in particular, the holding devices are designed for holding the flat materials (4, 5, 6) on one side or on both sides.

14. Device according to one of preceding Claims 10 to 13, characterized in that each supply device (1, 2) has clamping devices, in particular manipulators, for aligning or retaining the flat materials (4, 5, 6), wherein the clamping devices have, in particular, freely programmable motion axes.

15. Device according to one of preceding Claims 10 to 14, characterized in that the cutting and welding device comprises at least one laser head, wherein the at least one laser head (10) is designed for welding the flat materials (4, 5, 6), and / or for cutting the flat materials (4, 5, 6), and / or for weld seam preparation, in particular for carrying out an ablation step at the edge of the flat materials (4, 5, 6).

16. Device according to one of preceding Claims 10 to 15, characterized in that the cutting and welding device is designed as a laser portal, in particular as a 2D laser portal, and / or in that the laser head (10) is designed as a remote laser head or as a near-field laser head.

17. Device according to one of preceding Claims 10 to 16, characterized in that the device comprises a conveyor for removing waste from the device, wherein the conveyor comprises, in particular, a collecting hopper, and preferably comprises a suction extraction system.

18. Device according to one of preceding Claims 10 to 17, characterized in that the device comprises a transfer device between the delivery table and a shaping device.

19. Device according to one of preceding Claims 10 to 18, characterized in that the flat materials (4, 5, 6) are supplied from a feedstock store, in particular by means of flat material coils or by means of flat material plates.