Laser Trimming Cell Layout for Continuous Part Transfer
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Solution Overview
Problem
Laser cutting systems for sheet metal, such as those used in automotive manufacturing, face high capital costs and reduced efficiency due to the need for enclosed cells that require process time losses when parts are moved in and out, as the laser cannot operate with open doors to prevent light exposure.
Innovation Solution
A system with a single enclosed cell containing multiple laser cutting apparatuses and double doors that allow parts to enter and exit without opening the cell, ensuring continuous operation by keeping laser light contained and minimizing process time losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If an enclosed cell is used to contain laser light, then safety is improved by preventing light exposure to humans, but process time is reduced due to the need to close doors before operation and lose time moving parts in and out
Solution Approach 1:
The enclosed cell is segmented into multiple compartments, each with its own door. This allows one door to be open for part loading/unloading while another door remains closed to contain the laser light in its operational compartment, enabling simultaneous part handling and laser operation without compromising safety
Solution Approach 2:
The segmented cell design enables continuous laser operation by allowing part transfer through open doors in non-operational compartments while the laser actively cuts in a sealed compartment. This eliminates idle time between part changes and maintains continuous productive action
2Manufacturing precision
If a robotic laser or CNC arm is used for cutting, then cutting precision is improved, but capital costs and floor space requirements increase
Solution Approach 1:
Instead of using expensive robotic lasers or CNC arms, the invention employs a simple handheld laser cutting tool that operators control manually. This copying approach achieves sufficient cutting precision through operator skill rather than expensive automated positioning systems, significantly reducing equipment costs and floor space requirements
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 configuration reduces capital costs and process time by allowing continuous laser operation while parts are moved in and out, increasing overall efficiency and reducing the need for extensive floor space.
Implementation Method 1
A laser cutting apparatus, such as a robotic laser, is often used to trim or otherwise cut parts formed from sheet metal
Implementation Method 2
The laser cutting apparatus can continue cutting the first part while a second part enters or exits the cell
Data Source
AI summary
A system and method for laser cutting a plurality of parts, for example metal chassis components, using a plurality of laser cutting apparatuses is provided. The system includes a plurality of the laser cutting apparatuses disposed in a single enclosed cell for simultaneously trimming multiple parts. The system also includes at least one inner chamber and at least one set of double doors for transferring the parts in and out of the enclosed cell without any light escaping the cell. The parts are conveyed through the first door to the inner chamber while the second door is closed, and through the second door to the enclosed cell while the first door is closed. The system also includes robots continuously preloading and unloading the parts to maximize the laser trimming time.