Robotic Laser Etching for Panel Strain and Formability Testing
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Solution Overview
Problem
Current methods for formability testing of metal panels, such as those used in the automotive industry, rely on caustic chemicals for electro-chemical etching, which are hazardous, time-consuming, and operator skill-dependent, leading to inaccuracies and increased manufacturing delays.
Innovation Solution
A system and method for laser etching of metal or plastic substrates using autonomous or robotic laser etching devices to apply patterns like QR codes and dot patterns, allowing for precise strain measurements without hazardous chemicals, enhancing safety and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If electro-chemical etching with caustic chemicals is used, then circle patterns can be applied to metal panels for formability testing, but the process becomes hazardous, time-consuming, and operator skill-dependent
Solution Approach 1:
The patent replaces the electro-chemical etching process with a laser-based marking system. The laser directly marks circle patterns onto the metal panel surface without requiring chemical baths, eliminating hazardous chemical exposure while maintaining measurement precision for formability testing
Solution Approach 2:
The patent introduces a laser as an intermediary tool between the measurement system and the metal panel. Instead of using caustic chemicals to create the measurement pattern, the laser serves as a clean, controlled intermediary that deposits or ablates material to create the same circular grid pattern needed for strain analysis
2Measurement precision
If electro-chemical etching process is used, then circle patterns are applied to panels, but the process takes hours and causes manufacturing delays
Solution Approach 1:
The laser marking system eliminates the multi-step electro-chemical process (chemical application, waiting for reaction, rinsing, drying) and replaces it with a single rapid laser scanning operation that creates the same measurement pattern in minutes rather than hours
Solution Approach 2:
The laser marking system performs the pattern creation as a preliminary step before forming operations, allowing the measurement grid to be applied quickly and accurately without interfering with subsequent manufacturing processes, thereby maintaining productivity while enabling precise measurement
3Measurement precision
If manual electro-chemical etching is performed, then circle patterns can be created on panels, but the process becomes operator skill-dependent and inaccurate
Solution Approach 1:
The laser marking system is computer-controlled and automatically positions and creates the circular grid pattern based on programmed coordinates. The system serves itself by using automated feedback mechanisms to ensure consistent pattern accuracy without requiring operator skill for manual chemical application and timing
Solution Approach 2:
The patent replaces manual operator actions (applying chemicals, timing the etch, rinsing, inspecting) with an automated laser system that precisely controls pattern creation through digital positioning and automated scanning, eliminating operator skill dependency while maintaining high measurement precision
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 laser etching system provides accurate, rapid, and reliable strain measurements, reducing operator exposure to hazardous chemicals, minimizing waste, and improving manufacturing precision by enabling autonomous marking and deformation analysis, even under high-temperature processes like welding.
Implementation Method 1
A method for laser etching of a substrate surface to which a pattern has been applied in order that strain measurements may be determined
Implementation Method 2
The laser also is used to apply the one or more QR codes on the surface
Data Source
AI summary
A method, system and devices for autonomous marking of a substrate and for conducting formability measurements. The method, system and devices may be used to apply markings to a substrate, such as panels that are used to construct articles. The panels, for example, may be automobile panels. The markings preferably are applied on the panel autonomously with a laser etching, and with robot device that is controlled to form a precise pattern of indicia (e.g., dots), on the panel surface. An x, y, z, gantry coordinate system may be used to guide the operations of the robot device to position the device for etching at precise locations on the substrate surface. Once etched, the panels may be processed, such as, by stamping or cutting, and the deformation of the dot pattern may be used to determine strain and formability properties.