Vehicle Side Panel Laser Cutting with Parallel Robot Stations
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Solution Overview
Problem
Current laser cutting systems for vehicle structural components are inefficient, requiring long cutting times and increased logistics and personnel, which reduces productivity and necessitates larger manufacturing spaces due to the need for multiple laser cells and longer robot arms to handle large components.
Innovation Solution
A method utilizing multiple laser cutting stations with multi-axis robots, where components are processed in parallel, reducing cutting time and area requirements by allowing simultaneous cutting operations across multiple laser heads and robots, and incorporating trepanning tools for precise aperture finishing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single laser cutting system is used for large structural components, then the equipment investment is lower, but the cutting time is long and productivity is reduced
Solution Approach 1:
The patent divides the cutting process into multiple independent laser stations (first laser station, second laser station, etc.), each equipped with laser cutting heads that operate simultaneously on different sections of the component. This segmentation allows parallel processing, significantly reducing total cutting time while maintaining manageable equipment complexity at each station.
Solution Approach 2:
The patent transitions from sequential single-point cutting to multi-point parallel cutting by distributing laser heads across multiple stations arranged in space. This spatial dimensionality change enables simultaneous cutting operations on different areas of the large structural component, effectively increasing productivity without requiring a single overly complex system.
2Productivity
If multiple laser cells are used to increase productivity, then cutting time is reduced, but the manufacturing space and logistics requirements increase
Solution Approach 1:
The patent combines multiple laser cutting stations into an integrated manufacturing system that processes large structural components in a coordinated manner. By merging the functions of multiple laser cells into a unified workflow with synchronized operations, the system achieves high productivity while optimizing space utilization through shared fixtures, coordinated robot arms, and streamlined material flow.
3Adaptability or versatility
If longer robot arms are used to handle large components, then the coverage area is increased, but the system occupies more manufacturing space
Solution Approach 1:
The patent segments the cutting tasks across multiple laser stations, allowing each robot arm to operate within a compact, localized workspace. Instead of requiring one extremely long robot arm to cover the entire component, multiple shorter robot arms at different stations each handle specific sections, reducing the length requirement for individual robot arms while maintaining overall system coverage.
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 significantly increases productivity, reduces manufacturing costs, and synchronizes hot forming and cutting processes, allowing for efficient production of large structural components like unitary side panels with improved precision and reduced space requirements.
Implementation Method 1
cutting a first plurality of areas of the component with the plurality of laser cutting heads
Implementation Method 2
After heating, the blank is hot formed, and may then subsequently be quenched. This process is known as press-hardening. With such a process, a predominantly martensite microstructure may be created.
Implementation Method 3
Hot Forming Die Quenching (HFDQ) uses boron steel sheets to create stamped components with Ultra High Strength Steel (UHSS) properties
Data Source
Figure 1
Figure 2~3
Figure 4a~4b
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.