Vehicle Sheet Blanking with Backing-Die Scrap Drop Openings
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Solution Overview
Problem
Traditional car sheet blanking methods face issues with speed control, kerf engagement, scrap handling, and equipment reliability, leading to geometric accuracy errors, scrap disposal difficulties, and production line downtime due to the complexity of coordinating multiple cutting machines and conveyor systems.
Innovation Solution
A method involving a backing die with larger openings than the actual scraps, allowing for efficient laser cutting and scrap disposal without the need for dynamic conveyor adjustments, using a single Cartesian coordinate robot for cutting and transfer robots with vacuum suckers to manage sheets, ensuring flexibility and independence from single equipment malfunctions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple cutting machines and conveyor systems are coordinated for continuous blanking, then productivity is improved, but device complexity and reliability deteriorate due to coordination difficulties and equipment failure risks
Solution Approach 1:
The patent divides the blanking process into discrete steps with separate cutting machines operating on individual sheets rather than one continuous complex system. Each cutting machine works independently on its assigned sheet, segmenting the overall process to reduce coordination complexity while maintaining high throughput through parallel operation of multiple simpler units.
2Productivity
If multiple cutting machines and conveyor systems are coordinated for continuous blanking, then productivity is improved, but reliability worsens due to production line downtime from equipment failure
Solution Approach 1:
By segmenting the blanking process into independent stations, the patent ensures that a failure at one station does not halt the entire production line. Other stations can continue operating on their respective sheets, maintaining overall productivity and reliability through decentralized operation.
Solution Approach 2:
The patent introduces intermediate storage areas and transfer mechanisms between cutting stations that act as buffers. These intermediaries allow sheets to be moved and processed asynchronously, decoupling the stations so that one station's failure or slowdown does not immediately impact others, thereby improving production line reliability.
3Productivity
If speed control strategy is used for cutting operation, then productivity is improved, but manufacturing precision deteriorates due to geometric accuracy errors
Solution Approach 1:
The patent segments the high-speed cutting process into discrete, controlled steps at separate stations. Each station performs cutting operations on individual sheets with controlled feeding, allowing precision to be maintained at each step while the overall system achieves high productivity through parallel processing and elimination of speed control complexities in continuous operation.
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 enhances cutting accuracy, reduces scrap handling complexity, and maintains production line efficiency even if one cutting machine fails, as the system can operate independently with minimal disruption.
Implementation Method 1
cutting the group sheet with a laser beam
Implementation Method 2
laser cutting the group sheet based on the shape of car sheet, the cut scraps dropping
Implementation Method 3
transfer robots with vacuum suckers to manage sheets
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present invention discloses a method of car sheet blanking and a system of the same, wherein the blanking method comprises: firstly, nesting for car sheet material, and cutting it into group sheets with a shape and size confirmed by the multi length of the sheet; next, designing a backing die depending on scraps to be cut from the group sheet, and hollowing in areas corresponding to blanking openings in the backing die, in which the dimensions of the blanking openings are greater than that of the actual scraps to be cut; then, placing a group sheet onto the backing die; laser cutting the group sheet based on the shape of car sheet, the cut scraps dropping through the blanking openings in the backing die onto a scrap conveyor belt underneath; stacking the cut sheets. The present invention can effectively process scraps cut from sheets and improve the blanking efficiency.