Laser Weakening Line Skipping for Target Wall Thickness
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Solution Overview
Problem
Existing methods for producing weakening lines in components, such as airbag covering elements, are inefficient due to prolonged processing times and unnecessary material removal, especially when achieving target wall thicknesses.
Innovation Solution
A method and device utilizing a laser-based material removal process that includes guiding and skipping steps, where the laser is guided over predefined contours to achieve target wall thicknesses and then skipped over completed portions, allowing for increased speed and efficient production of weakening lines by deactivating the laser beam during skipping and using lead-in and lead-out sections for synchronization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the laser removal apparatus continuously guides over the entire predefined contour to ensure complete material removal, then the weakening line production reliability is improved, but the processing time increases and productivity deteriorates
Solution Approach 1:
The system continuously monitors the actual wall thickness during laser processing and uses this feedback information to determine when portions of the contour have achieved the target wall thickness. This real-time feedback enables the skipping mechanism to reliably identify completed portions without compromising the overall reliability of the weakening line production.
Solution Approach 2:
The processing path is made dynamic by allowing the system to adaptively skip portions of the contour based on real-time thickness measurements. Instead of following a fixed continuous path, the removal apparatus dynamically adjusts its trajectory to jump over completed portions, thereby improving productivity while maintaining reliability through continuous monitoring.
2Manufacturing precision
If the laser removal apparatus processes all portions of the contour to ensure complete weakening line formation, then the manufacturing precision is improved, but the processing time increases and productivity deteriorates
Solution Approach 1:
The system implements a skipping mechanism that allows the laser removal apparatus to rush through portions of the contour that have already achieved the target wall thickness. By identifying completed portions through real-time monitoring and skipping them, the system reduces processing time while maintaining manufacturing precision by ensuring that all necessary portions are properly processed before skipping.
Solution Approach 2:
The system performs preliminary monitoring and evaluation of wall thickness during the processing sequence, allowing it to identify portions that have already met the target thickness criteria. This preliminary assessment enables the system to make informed decisions about which portions can be skipped, thereby reducing overall processing time while maintaining precision.
3Manufacturing precision
If the laser beam remains activated during the entire contour traversal to ensure continuous material removal, then the weakening line quality is improved, but the energy consumption increases and productivity deteriorates
Solution Approach 1:
The laser beam operation is converted from continuous to periodic action. The system activates the laser beam only when material removal is actually needed (when portions have not yet achieved target wall thickness) and deactivates it when skipping completed portions. This periodic activation pattern maintains weakening line quality by ensuring proper laser application where needed while reducing overall energy consumption by eliminating unnecessary laser operation during skipping sequences.
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 significantly reduces processing time by skipping completed portions and optimizing movement paths, enabling rapid and efficient production of weakening lines that meet target wall thicknesses, thus enhancing the manufacturing efficiency and quality of components like airbag covering elements.
Implementation Method 1
The removal apparatus can be a laser that carries out the removal of the material by means of the laser beam by way of material heating.
Implementation Method 2
carries out the removal of the material by means of the laser beam by way of material heating
Data Source
AI summary
A method for producing a weakening line in a surface of a component. The method comprises a guiding step and a skipping step. In the guiding step, a removal apparatus for removing a material of the surface is guided over a plurality of segments of a predefined line-shaped contour by means of an activated laser beam in order to produce a desired wall thickness for at least one of the segments so as to produce the weakening line. In the skipping step, the segment is skipped if the segment has the desired wall thickness.