Laser Blanking and Stamping Integration for Steel Coil Processing
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Solution Overview
Problem
Traditional automobile plate die uncoiling and blanking lines require multiple production lines and extensive space for storage and conveyance, leading to inefficiencies and high investment costs, especially when producing small-size parts or personalized vehicle models.
Innovation Solution
An uncoiling, blanking, and forming method that integrates laser blanking with stamping, reducing intermediate steps and space requirements by using a laser cutting head to cut steel coils directly into shaped sheets, which are then stamped and formed, utilizing a manipulator or robot for efficient transfer and processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional die blanking is used, then manufacturing precision is improved, but device complexity and investment cost increase due to multiple production lines and extensive storage space requirements
Solution Approach 1:
The patent combines the blanking line and stamping forming line into a single integrated production line. The laser blanking device and stamping press are arranged in sequence within one line, eliminating the need for separate production lines. This merging reduces device complexity and investment cost while maintaining manufacturing precision through the use of laser blanking technology.
Solution Approach 2:
The patent replaces traditional mechanical die blanking with laser blanking technology. The laser cutting head uses optical energy instead of mechanical forces to cut the steel coil, eliminating the need for complex die systems. This substitution reduces device complexity and investment cost while maintaining or improving blanking quality through the precision of laser technology.
2Manufacturing precision
If traditional die blanking is used, then manufacturing precision is improved, but loss of time increases due to stacking, packing, transportation, and positioning operations
Solution Approach 1:
The patent implements continuous production by eliminating intermediate steps between blanking and stamping. The laser blanking device cuts the steel coil continuously, and the stamped parts are formed immediately in sequence without interruption. This continuous action eliminates the time losses associated with stacking, packing, transportation, and positioning operations while maintaining manufacturing precision.
Solution Approach 2:
The patent performs preliminary positioning and preparation of the steel coil within the integrated line before blanking and stamping. The coil is fed and positioned continuously through the line, eliminating the need for subsequent positioning operations after blanking. This preliminary action reduces time loss by ensuring materials are ready for the next operation without interruption.
3Device complexity
If laser blanking is used, then device complexity is reduced, but productivity decreases compared to traditional die blanking
Solution Approach 1:
The patent merges the blanking line and stamping forming line into one integrated production line, allowing simultaneous operation of laser blanking and stamping press. This merging enables the system to achieve productivity equivalent to or exceeding traditional die blanking by eliminating bottlenecks and intermediate handling steps, while maintaining the simplicity of laser blanking technology.
Solution Approach 2:
The patent ensures continuous operation of the laser blanking device and stamping press within the integrated line. The steel coil is fed continuously through the line, and both blanking and stamping operations proceed without interruption. This continuity of useful action maximizes productivity by eliminating idle time and ensuring constant material flow through the production process.
4Productivity
If multiple production lines are used, then productivity is improved, but area of stationary object increases due to extensive space for storage and conveyance
Solution Approach 1:
The patent combines multiple production functions into a single integrated line, eliminating the need for separate blanking and stamping lines. This merging reduces the plant area required by consolidating storage, conveyance, and processing functions into one compact arrangement, while maintaining high productivity through continuous operation and elimination of intermediate handling steps.
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
This method simplifies the workflow, reduces space needed for transfer, and matches production rates between laser blanking and stamping lines, enabling flexible production without the need for extensive die development and storage, suitable for small-size and personalized vehicle models.
Implementation Method 1
laser blanking, wherein the steel coil enters the blanking region, is cut by a laser cutting head by way of laser blanking to form sheets with a required shape
Data Source
AI summary
An uncoiling, blanking and forming method includes the steps of: 1) uncoiling a steel coil, wherein a steel strip uncoiled from the steel coil is cleaned and straightened and is fed by a pinch roller to a blanking region; 2) laser blanking, wherein the steel coil enters the blanking region, is cut by a laser cutting head by way of laser blanking to form sheets with a required shape, with waste materials falling down and being conveyed to the outside; 3) outputting the sheets, wherein the sheets pass over a magnetic telescopic belt conveyor, and then carried by means of a manipulator or a robot to a stamping process; 4) stamping forming, wherein the sheets are stamped to form workpieces; and 5) checking, wherein the workpieces are checked and put in storage. The present invention can achieve joining-up in series of a blanking line and a stamping forming line and realize matching therebetween, and can reduce intermediate steps such as stacking, packing, transportation, positioning, unpacking, carrying, and centring of sheets and stamping-formed workpieces, and also can reduce the room required for transfer, simplify the work flow and joins up procedures in series, to directly machine a material coil by laser blanking to form formed parts.