Laser Scan Correction for Vehicle Trim Breaking Lines
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Solution Overview
Problem
Existing methods for producing predetermined breaking lines in vehicle interior trim parts require precise alignment of the trim parts to sensors, leading to increased time expenditure and reduced productivity due to the need for exact positioning.
Innovation Solution
A method and device utilizing a sensor matrix and laser scanning system that allows for the vehicle interior trim part to be roughly positioned, with a camera determining the actual position of the breaking line, and a diffuser ensuring homogeneous sensitivity across the sensor matrix, enabling the laser scanning device to create the breaking line accurately without precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precise alignment of trim parts to sensors is required, then manufacturing precision is improved, but productivity deteriorates due to increased positioning time
Solution Approach 1:
The patent replaces the mechanical alignment system with an optical detection system. Instead of using mechanical fixtures and precise manual positioning, the invention uses a sensor matrix to optically detect the actual position of the breaking line and automatically adjusts the laser scanning parameters accordingly. This substitution of mechanical positioning with optical sensing and automated adjustment resolves the contradiction by eliminating time-consuming manual alignment while maintaining high precision.
Solution Approach 2:
The patent changes the parameter of position detection from fixed/pre-defined to dynamic/actual. The system detects the actual position of the breaking line using the sensor matrix and adjusts the laser scanning parameters (position, speed, power) based on the detected actual position rather than relying on pre-set parameters. This dynamic parameter adjustment allows the system to maintain high precision while adapting to variations in part positioning, thereby improving productivity.
2Measurement precision
If a sensor matrix is used instead of a single sensor, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent segments the detection function across multiple sensors arranged in a matrix configuration. Each sensor in the matrix independently detects the position of the breaking line at its specific location, and the control system integrates these segmented measurements to determine the overall actual position. This segmentation approach improves measurement precision by providing multiple data points while managing complexity through modular sensor arrangement and systematic data integration.
Solution Approach 2:
The sensor matrix serves multiple functions simultaneously: it detects the position of the breaking line, verifies the correct placement of the trim part, and provides data for automated laser parameter adjustment. This multi-functionality justifies the increased device complexity by delivering comprehensive measurement capabilities that improve both precision and process control in a single integrated system.
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 approach reduces the time required for positioning and enhances productivity by allowing for flexible and efficient production of breaking lines on various trim parts, even those with complex contours, by using a sensor matrix and laser scanning system.
Implementation Method 1
a laser beam scanning across the panel removes material along a predetermined breaking line
Implementation Method 2
material removal along a predetermined breaking line that defines the breaking points is sensor-monitored or sensor-controlled
Implementation Method 3
individual sensors of the sensor matrix detect a portion of the laser beam transmitting through the panel
Implementation Method 4
a diffuser upstream of the sensor matrix, which scatters the laser radiation incident on the sensor matrix
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a device (0) and a method for producing a predetermined breaking line (2) in a vehicle interior trim panel (1) using a scanning laser beam (S). The actual position of the vehicle interior trim panel (2), held in a working plane (A), relative to a laser scanning device (6), is captured by a camera (8), and the actual position of the predetermined breaking line is derived. A stored target position, for a scan pattern corresponding to the predetermined breaking line, is corrected to the actual position, so that when the scan pattern is scanned, the predetermined breaking line (2) is produced at a predetermined position on the vehicle interior trim panel (1). A shift in the position of the scan pattern is possible because a sensor matrix (3) with an upstream diffuser (12) is used, which can detect transmitting components of the laser beam (S) independently of the position of the laser beam along the scan pattern.