Sheet Material Joining and Shaping With Scrap Reuse
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Solution Overview
Problem
Current methods for producing construction profiles are inefficient in terms of energy usage, emissions, and resource management, and often result in unnecessary scrap during production.
Innovation Solution
A method and device for joining and shaping flat materials, where materials with different properties are fed into a cutting and welding process, allowing for the production of customized composite workpieces with reduced energy consumption and emissions by minimizing waste through efficient reuse and recycling of materials, and enabling the creation of complex profiles with precise alignment and shaping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional methods are used for producing construction profiles, then production can be carried out with standard processes, but energy consumption is high and unnecessary scrap is generated
Solution Approach 1:
The production process is segmented into distinct phases: feeding flat materials from supply devices, holding on input-side holding device, aligning at joining edges, welding connections, transporting to delivery table, and separating residual pieces. This segmentation allows each step to be optimized independently for energy efficiency while maintaining overall process simplicity through systematic organization.
Solution Approach 2:
Residual pieces of flat materials are separated after welding and fed back into the supply device for subsequent repeated removal steps. This recovery process eliminates waste by reusing material remnants, reducing energy consumption associated with producing new material, and maintaining ease of manufacture through automated recycling integration.
2Object-generated harmful factors
If conventional production methods are used, then standard manufacturing processes can be applied, but emissions and resource management are inefficient
Solution Approach 1:
The process enables continuous production by feeding flat materials sequentially, performing welding operations without interruption, and immediately recycling residual pieces back into the supply device. This continuous operation eliminates idle time and associated emissions while maintaining high productivity through uninterrupted material flow and automated processes.
Solution Approach 2:
Residual pieces are continuously recovered and reused in subsequent production cycles, eliminating waste disposal emissions and reducing the need for new material production. This closed-loop system improves resource management efficiency while maintaining high productivity through automated material recycling integration.
3Loss of substance
If flat materials are completely cut off during production, then material can be separated for different uses, but unnecessary scrap is generated and resources are wasted
Solution Approach 1:
Instead of completely discarding residual pieces, the system separates and recycles them by feeding back into the supply device for subsequent repeated removal steps. This approach minimizes material waste while maintaining versatility by allowing residual pieces to be reused in different production configurations and composite workpiece designs.
Solution Approach 2:
The system changes the utilization parameter of residual materials from complete disposal to partial reuse. By adjusting the feeding mechanism to repeatedly remove and reuse residual pieces, the system transforms waste into valuable resources while maintaining adaptability in material composition and composite workpiece fabrication.
4Adaptability or versatility
If different flat materials are joined to form composite workpieces, then customized profiles with optimized properties can be produced, but the production process becomes more complex
Solution Approach 1:
The production process is segmented into standardized, repeatable steps: feeding specific flat materials from designated supply devices, holding on input-side device, aligning at joining edges, welding connections, transporting to delivery table, and separating residual pieces. This segmentation manages complexity by organizing multi-material joining into systematic phases while enabling high adaptability for customized composite workpiece production.
Solution Approach 2:
The holding devices and welding system are designed to handle multiple types of flat materials universally. The input-side holding device can hold different materials, the welding device can join various material combinations, and the system can produce diverse composite workpieces using the same core process steps, thereby managing complexity through universal equipment design.
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 enables the production of customized composite workpieces with optimized weight and stability, reducing energy and emissions during production and use, while minimizing waste and allowing for the creation of complex profiles with precise control over material properties.
Implementation Method 1
The at least one laser head (10) is used for welding the flat materials (4, 5) to one another at the joining edge (15)
Implementation Method 2
The at least one laser head (10) is designed for welding the flat materials (4, 5), for cutting the flat materials (4, 5) and/or for carrying out a shaping process
Data Source
AI summary
A method for joining and shaping flat materials. At least one first flat material and at least one second flat material are fed to a cutting and welding device in respective supply devices, each associated with one flat material.