Multi-Robot Laser Cutting Layout for Large Vehicle Panels
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Solution Overview
Problem
Current laser cutting systems for vehicle structural components are inefficient, requiring long cutting times and large manufacturing spaces, leading to increased logistics and personnel needs, especially for large components like door frames, which disrupt the productivity balance with hot forming processes.
Innovation Solution
A method and system utilizing multiple laser cutting stations with multi-axis robots and fixtures, allowing simultaneous cutting operations by multiple laser heads at each station, reducing the time and space requirements, and incorporating grippers for automated component handling and inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single laser cutting station is used, then the device complexity is low, but the cutting productivity is insufficient and cannot match hot forming speeds
Solution Approach 1:
The system divides the cutting operation into multiple independent laser cutting stations (first laser cutting station and second laser cutting station), each equipped with its own laser cutting head and multi-axis robot. This segmentation allows parallel processing of different cutting tasks, thereby increasing overall cutting productivity while maintaining manageable complexity at each station.
Solution Approach 2:
The system combines multiple laser cutting heads and multi-axis robots within a single integrated manufacturing system. By merging these resources and coordinating them through a centralized control system, the patent achieves high cutting productivity that matches hot forming speeds while optimizing the use of equipment and reducing total device complexity compared to fully separate systems.
2Productivity
If multiple laser cutting stations are used to increase productivity, then the cutting speed increases, but the manufacturing space and logistics requirements increase
Solution Approach 1:
The patent transitions from a linear sequential arrangement of laser cutting stations to a multi-dimensional integrated system where multiple stations are spatially organized and coordinated through a centralized control system. This dimensional reorganization allows parallel cutting operations to occur simultaneously within a compact footprint, increasing cutting speed without proportionally increasing manufacturing space requirements.
3Loss of time
If traditional single-station laser cutting is used, then the equipment investment is lower, but the manufacturing time and production costs increase
Solution Approach 1:
The system ensures continuous useful action by coordinating multiple laser cutting stations to operate simultaneously on different components or different sections of the same component. The centralized control system manages task allocation and resource coordination to eliminate idle time, ensuring that all laser cutting heads and robots are continuously engaged in productive cutting operations, thereby reducing total manufacturing time and increasing production efficiency.
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
Enhances cutting productivity, reduces manufacturing space, and lowers costs by synchronizing cutting with hot forming speeds while minimizing manual handling, thus optimizing the manufacturing process for vehicle structural components.
Implementation Method 1
a laser cutting head mounted on a multi-axis robot
Implementation Method 2
cutting a first plurality of areas of the steel component with the plurality of laser cutting heads
Data Source
AI summary
Methods and systems for laser cutting of components are disclosed herein. Examples are specifically suited for laser cutting relatively large components of e.g. a vehicle framework such as a unitary side panel of a vehicle door. Multiple robots may perform laser cutting operations substantially simultaneously.