Hot Stamping Laser Cutting Feedback Loop for Precision
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Solution Overview
Problem
Current hot stamping processes are inefficient due to low cycle rates of laser cutting systems, which limits the widespread adoption of prefabrication for hot stamping, resulting in high scrap rates and deviations from nominal component sizes.
Innovation Solution
A system integrating a laser cutting station, storage station, furnace, press, and measuring station with a feedback loop that allows for real-time measurement and adjustment of cut components to minimize deviations from nominal sizes, optimizing the hot stamping process by providing 100% measurement and correction of component shapes and cutouts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser cutting systems are used for prefabrication of plates for hot stamping, then manufacturing precision of component shapes and cutouts is improved, but productivity is reduced due to low cycle rates of about ten plates per minute
Solution Approach 1:
The laser cutting station performs preliminary cutting of plates to predetermined shapes and cutouts before hot stamping. This preliminary action enables precise contour definition while allowing the cutting process to operate independently at its optimal cycle rate, decoupling it from the hot stamping cycle time.
Solution Approach 2:
The system segments the manufacturing process into distinct stations: laser cutting station for contour preparation, storage station for plate management, and hot stamping press for forming. This segmentation allows each station to operate at its own optimal speed and cycle rate, with the laser cutting station achieving high precision without being bottlenecked by the slower hot stamping cycle.
2Manufacturing precision
If trimming is performed in the hot stamping tool, then manufacturing precision is improved, but device complexity increases due to additional tooling requirements
Solution Approach 1:
The trimming function is extracted from the hot stamping tool and relocated to a separate laser cutting station. This extraction simplifies the hot stamping tool design by removing complex trimming mechanisms, while the laser cutting station independently performs precise contour cutting and cutout creation before the plates enter the hot stamping process.
3Device complexity
If conventional hot stamping processes are used without feedback control, then device complexity is reduced, but manufacturing precision deteriorates due to deviations from nominal component sizes
Solution Approach 1:
A feedback control system connects the measuring station to the laser cutting station. The measuring station measures actual component dimensions after hot stamping, and this measurement data is fed back to the laser cutting station's control module, which automatically adjusts cutting parameters to compensate for deviations and ensure nominal component sizes are achieved.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system significantly reduces scrap components and ensures accurate formation of components by continuously monitoring and adjusting the cutting process, improving the efficiency and precision of hot stamping.
Implementation Method 1
a laser cutting station for cutting a plate from a supplied steel-sheet material
Implementation Method 2
a furnace for heating the plate to a predetermined deformation temperature
Data Source
AI summary
A system for producing components by hot stamping includes a laser cutting station for cutting a plate from a supplied steel-sheet material. The plate has at least one of a predetermined edge-contour and a predetermined cut-out portion for forming a shape of the component. The plate is stored in a storage station, and is subsequently transferred to a furnace station for heating the plate to a predetermined deformation temperature. A press having a hot stamping tool forms the plate into the shape of the component. The system also includes a measuring station disposed downstream of the press for obtaining measurement data relating to the shape of the component that is formed from the plate. The measurement data obtained using the measuring station is provided to a control module of the laser cutting station via a feedback loop.