Parallel Laser Cutting Cells for Large Vehicle Side Panels
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Solution Overview
Problem
Current laser cutting systems for cutting structural components in vehicles are inefficient, requiring long cutting times and large manufacturing areas, which reduces productivity and increases logistical challenges.
Innovation Solution
A method and system that utilize multiple laser cutting stations with multiple multi-axis robots and laser cutting heads, allowing simultaneous cutting operations and reducing the area required for cutting operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single laser cutting station with one laser cutting head is used, then the device complexity is low, but the cutting time is long and productivity is low
Solution Approach 1:
The patent divides the cutting system into multiple independent laser cutting stations (first laser station, second laser station) with multiple multi-axis robots and laser cutting heads at each station. This segmentation allows parallel cutting operations on different components simultaneously, dramatically increasing productivity while keeping each individual station manageable in complexity
Solution Approach 2:
The patent combines multiple laser cutting heads and multi-axis robots into integrated cutting stations where multiple cutting operations can occur simultaneously on the same component or different components. This merging of cutting resources resolves the contradiction by achieving high productivity through parallel processing while maintaining organized system architecture
2Productivity
If multiple laser cutting stations with multiple robots are used, then productivity increases and cutting time decreases, but the manufacturing area required increases
Solution Approach 1:
The patent utilizes vertical space and three-dimensional positioning by employing multi-axis robots that can move cutting heads in multiple dimensions. This allows multiple cutting operations to be stacked or arranged in space rather than requiring proportional horizontal area expansion, resolving the contradiction between productivity and manufacturing area
Solution Approach 2:
The patent arranges multiple laser cutting heads and robots in a compact, nested configuration where cutting stations are positioned to share space efficiently. The multi-axis robots can service multiple cutting heads from centralized positions, reducing the overall footprint while maintaining high productivity through parallel operations
3Loss of time
If traditional single-station laser cutting is used, then the system is simple to operate, but the cutting time is long and efficiency is low
Solution Approach 1:
The patent implements automated component handling and positioning systems that prepare components for cutting before the actual cutting process begins. Multi-axis robots automatically load components onto fixtures, position them precisely, and coordinate between multiple cutting stations, reducing manual intervention while dramatically cutting overall processing time
Solution Approach 2:
The patent designs the multi-station system with continuous material flow and parallel processing where multiple cutting operations occur simultaneously without idle time. Components are continuously fed through the system with minimal waiting, and cutting heads operate continuously on different components, eliminating the time losses inherent in sequential single-station processing
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
The system significantly reduces cutting time, increases productivity, and minimizes the required manufacturing area, enabling more efficient processing of hot formed components while maintaining high precision and quality.
Implementation Method 1
a laser cutting head for cutting a steel component
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.