Remote Laser Welding Cell Layout for Continuous Workpiece Changeover
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Solution Overview
Problem
Conventional remote laser processing systems face inefficiencies due to long non-productive times and suboptimal utilization of laser sources and tools, leading to increased costs and reduced profitability, primarily because the laser processing must be interrupted to bring workpieces in and out of the protective housing.
Innovation Solution
A remote laser processing system with a protective housing containing a working robot, two processing stations, and a buffer area acting as an automatable workpiece lock, where the working robot performs processing at one station while the handling robot prepares the other station and manages the buffer area, allowing continuous operation without interrupting the processing flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single processing station is used within the protective housing, then the system structure is simple, but the laser source and processing optics are underutilized due to long non-productive times when workpieces need to be brought in and out
Solution Approach 1:
The single processing station is divided into two processing stations (first processing station and second processing station) within the protective housing. This segmentation allows the working robot to process workpieces at one station while the handling robot prepares the other station, eliminating idle time for the laser source and optics.
Solution Approach 2:
The handling robot performs preliminary actions by preparing the second processing station in advance while the working robot is processing at the first station. This includes positioning workpieces and ensuring the station is ready for immediate processing, thus eliminating non-productive waiting time.
2Productivity
If workpiece loading and unloading is performed during laser processing, then continuous material flow is possible, but the laser processing must be interrupted causing non-productive times
Solution Approach 1:
A buffer area is introduced as an intermediary between the external environment and the processing stations. The buffer area stores workpieces and allows the handling robot to exchange workpieces without requiring the protective housing to be opened during processing, thus maintaining continuous operation.
Solution Approach 2:
Workpieces are pre-positioned in the buffer area and the handling robot prepares the second processing station in advance. This preliminary preparation ensures that when the working robot finishes at the first station, the second station is already ready with a workpiece, eliminating idle time.
3Reliability
If a protective housing is used to contain laser radiation, then safety is ensured, but workpiece exchange requires opening the housing causing processing interruptions
Solution Approach 1:
The buffer area serves as a mediator that decouples the workpiece exchange operation from the protective housing. Workpieces can be loaded into and unloaded from the buffer area without opening the housing, and the handling robot can transfer workpieces between the buffer and processing stations internally, maintaining both safety and continuity.
Solution Approach 2:
The system transitions from a single-dimension linear process (load-process-unload) to a two-dimension workflow with parallel processing stations and a buffer area. This dimensional change allows simultaneous processing and preparation operations within the protective housing.
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a laser remote processing system, in particular a laser remote welding system having a laser cell (20) surrounded by a protective housing (22), in which a working robot (A) having a remote laser tool and a first processing station (B1) in the working region of the working robot (A) are arranged. In order to improve the efficiency of the system, a second processing station (32) in the working region of the working robot (A), and at least one handling robot (H1, H2) are furthermore arranged within the protective housing (22), it being possible to reposition workpieces between the first processing station (B1) or the second processing station (32) and a buffer region (P1) with said handling robot. The buffer region (P1) is set up to receive workpieces (W) and is integrated into the protective housing (22) as an automatably actuable workpiece lock (ZP1).