Laser Cutting System for Small-Batch Metal Plate Processing
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Solution Overview
Problem
Conventional die blanking methods for automobile metal plate processing are costly and inefficient for small-batch production, requiring extensive space and high equipment investment, and face challenges in aligning cuts during laser cutting operations.
Innovation Solution
A metal plate loading/unloading and cutting system with a block cart, sheet cart, and laser cutting head on a guide rail, utilizing a carrying and stacking robot, waste material conveying device, and a replaceable liner die with a 2D sensor for automatic correction of cutting paths, allowing for efficient processing and recycling of waste materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If die blanking method is used for large-scale mass production, then high production efficiency is achieved, but high costs in manufacturing and storing blanking dies occur
Solution Approach 1:
The patent replaces the mechanical die blanking system with a laser cutting system. The laser cutting head uses optical energy to cut metal plates instead of mechanical dies, eliminating the need for manufacturing and storing expensive blanking dies while maintaining high production efficiency of 4,000,000-6,000,000 sheets per year
Solution Approach 2:
The patent uses a programmable laser cutting system that can replicate different cutting patterns through software control. Instead of manufacturing physical dies for each vehicle model, the system uses digital templates and control programs to reproduce various sheet metal shapes, significantly reducing manufacturing costs
2Productivity
If die blanking method is used for large-scale mass production, then high production efficiency is achieved, but high space requirements for die stacking and maintenance room occur
Solution Approach 1:
The patent replaces the mechanical die blanking system with a laser cutting system, eliminating the need for extensive die storage facilities. The laser cutting head and control system occupy minimal space compared to the large press equipment and die stacking areas required by traditional die blanking methods
Solution Approach 2:
The laser cutting system serves multiple functions: it can cut various shapes, sizes, and thicknesses of metal plates using the same equipment through programmable control. This multi-functionality eliminates the need for multiple specialized dies and their associated storage spaces
3Productivity
If die blanking method is used for large-scale mass production, then high production efficiency is achieved, but plant building investments due to large press equipment and equipment foundation occur
Solution Approach 1:
The patent replaces the heavy mechanical press equipment with a lightweight laser cutting system. The laser generator, cutting head, and positioning system weigh significantly less than the large press equipment and substantial foundation required for die blanking operations, reducing plant building investments
4Productivity
If multiple laser heads are used for high-speed cutting, then cutting speed is improved, but alignment of cuts generated by multiple devices becomes difficult
Solution Approach 1:
The patent divides the cutting process into two stages: first, a rapid positioning laser head performs rough cutting to separate the sheet metal into approximate shapes; second, a precision laser head performs fine cutting to achieve accurate dimensions and alignment. This segmentation allows each laser head to be optimized for its specific function while working in coordination
Solution Approach 2:
The patent introduces a positioning mechanism and control system as an intermediary between multiple laser heads. This intermediary coordinates the movements and cutting paths of multiple laser heads, ensuring precise alignment of cuts by continuously monitoring and adjusting their positions relative to each other
5Productivity
If multiple laser heads are used for high-speed cutting, then cutting speed is improved, but huge configuration and occupied area of multiple sets of laser cutters occur
Solution Approach 1:
The patent merges multiple laser cutting functions into a single integrated laser cutting system. By combining the laser source, control system, and cutting head into one unit that can perform multiple cutting operations sequentially or simultaneously on different sections of the metal plate, the system achieves high productivity without requiring multiple separate laser cutter configurations
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 system reduces costs and space requirements, enhances material utilization, and enables efficient production of small-batch vehicle models by optimizing the cutting process and utilizing waste materials effectively.
Implementation Method 1
a laser cutting head (7) moving over the two cutting stations (51, 61) along its guide rail
Implementation Method 2
the cutting speed (for a steel plate with a thickness less than 1.5 mm, the cutting speed can be kept not less than 20 m/min when using a 4 KW optical fiber laser generator)
Data Source
AI summary
A metal plate loading/unloading and cutting method and system comprises: a block cart and a sheet cart both of which are arranged on a guide rail; a cutting operation unit arranged at one side of the guide rail; a carrying and stacking robot arranged between the cutting operation unit and the guide rail of the block cart and the sheet cart, a robot external shaft being parallel to the cart guide rail and extending over two fast moving table waiting stations of the cutting operation unit; and a waste material conveying device arranged below the two cutting stations of the cutting operation unit. The present invention can effectively increase material utilization efficiency and further enlarge the range in production and machining, and is especially suitable for providing production of small-batch vehicle models and trial production of new vehicle models.