AI-Guided Straightening of Hardened Metal Workpieces

The patent replaces conventional mechanical bending systems with a laser-based heating system. The laser heats specific areas of the hardened workpiece, creating thermal expansion and contraction that induces bending without mechanical contact. This substitution eliminates the destructive mechanical stress that would otherwise damage the hardened material while achieving the desired geometric correction.

The patent changes the physical state and properties of the workpiece material by applying localized thermal energy. By controlling the laser heating parameters (temperature, heating rate, cooling rate), the material undergoes phase transformations and stress relief that enable geometry correction without compromising the hardened structure. The thermal parameters are precisely controlled to achieve straightening while preserving material integrity.

Instead of applying heat treatment to the entire workpiece, the patent applies laser heating only to the specific localized areas that require straightening. This localized approach corrects geometric deformations without subjecting the entire workpiece to heat treatment, thereby preserving the overall hardness and significantly reducing processing time compared to conventional full heat treatment methods.

The patent skips the conventional multi-step heat treatment process by using direct laser heating to achieve straightening in a single, rapid operation. The laser can be quickly positioned and moved along the workpiece, enabling fast correction of geometric deformations without the time-consuming cycles of conventional heat treatment, thus reducing total processing time while maintaining material properties.

The patent replaces manual mechanical straightening operations with an automated laser-based system. The laser is controlled by computer software that calculates the precise heating parameters and movement paths needed for straightening. This automation eliminates the need for experienced workers to apply informal knowledge and removes workers from direct contact with hazardous hardened materials, thereby improving both consistency and safety while achieving the desired straightness.

The system incorporates automated measurement and control capabilities that allow the workpiece itself to guide the straightening process. Sensors detect the actual geometric deviations, and the control system automatically adjusts the laser heating parameters based on the measured deviations, eliminating the need for manual assessment and decision-making by experienced workers. This self-adjusting capability ensures consistent results without relying on human expertise.

The patent uses laser heating to apply thermal energy only to the specific localized areas of the workpiece that require straightening, rather than applying heat broadly as with a gas burner. The laser beam can be precisely positioned and focused on small zones, creating localized thermal expansion and contraction that induces bending without heating the entire workpiece. This localized heating approach eliminates unwanted heat input that would otherwise affect other areas of the workpiece and compromise material properties.

The patent replaces the gas burner heating system with a laser-based heating system. The laser provides more precise and controllable thermal energy delivery compared to the diffuse heat from a gas burner. The laser can be rapidly positioned and its power precisely controlled, enabling targeted heating that achieves straightening without the excessive and unwanted heat input characteristic of gas burner methods. This substitution also enables automation, eliminating the need for skilled manual operation.