Laser Sheet Cutting With Breakable Scrap Joints for Easy Unloading
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Solution Overview
Problem
The existing laser cutting processes face difficulties in efficiently removing and disposing of scrap skeleton regions from metal sheets, as they can hang down between support bars and cause collisions with grippers or rakes, making unloading challenging, and the large size of unshredded scrap skeletons poses disposal problems.
Innovation Solution
A laser cutting process that introduces cutting and separating lines into a metal sheet to create joints of small height between residual parts, allowing for easy removal and separation of the residual parts without tilting, using a laser cutting machine with a support system and a control device to manage the cutting and separation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the scrap skeleton is completely cut into smaller pieces, then it can be disposed of more easily, but the unloading process becomes more difficult due to collision with grippers or rakes
Solution Approach 1:
The scrap skeleton is divided into smaller regions through cutting lines, but these regions remain connected via connecting lines that create bridges between support bars. This segmentation allows the scrap to be handled as unified portions rather than completely separate pieces, preventing collision with removal unit components during unloading while still enabling easy disposal of smaller manageable portions.
Solution Approach 2:
The connecting lines act as intermediaries between the cut scrap regions and the support bars. These connecting lines create bridge structures that span between support bars, providing mechanical support to the scrap skeleton regions and preventing them from hanging down and colliding with grippers or rakes during the unloading process.
2Ease of operation
If the scrap skeleton is not shredded, then the unloading process is simpler, but the disposal becomes problematic due to large size
Solution Approach 1:
The scrap skeleton is segmented into smaller regions through cutting lines, reducing the overall size and making disposal easier. However, the segmentation is not complete - connecting lines maintain bridges between support bars, allowing the segmented portions to be handled as unified structures during unloading, thus maintaining operational simplicity while achieving disposal-friendly sizing.
3Manufacturing precision
If complete cutting through the metal sheet is performed, then the residual part can be fully separated, but the removal process becomes more difficult due to tilting of portions
Solution Approach 1:
The connecting lines are extracted as residual material that intentionally remains after the cutting process. By leaving these connecting lines in place, the patent creates bridge structures that prevent portions from tilting during removal. This extraction approach maintains complete separation of workpieces while preserving structural integrity of the scrap skeleton for easy handling.
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
Enables reliable removal and shredding of residual metal sheets, preventing tilting of portions, facilitating disposal, and increasing productivity by over 3% compared to traditional methods that require complete cutting through the metal sheet.
Implementation Method 1
introducing at least one cutting line for separating the at least one workpiece from the residual part using the laser cutting machine, and introducing at least one separating line into the residual part using the laser cutting machine
Data Source
AI summary
A laser cutting process for cutting at least one workpiece out of a metal sheet while leaving a residual part is provided. The process includes arranging the metal sheet on a support of a laser cutting machine, introducing at least one cutting line for separating the at least one workpiece from the residual part using the laser cutting machine, and introducing at least one separating line into the residual part using the laser cutting machine. In a main region of the separating line, the residual part is cut through. In a connecting region of the separating line, at least one joint remains between mutually adjacent portions of the residual part. The joint has a height that is smaller than a thickness of the metal sheet. The process further includes removing the residual part from the support, and separating the portions of the residual part from one another.