Vehicle Trim Break Line Laser Scanning With Sensor Matrix Verification
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Solution Overview
Problem
Existing methods for creating predetermined breaking lines in vehicle interior trim parts require precise positioning of the trim part relative to a sensor array, which is cumbersome and limits flexibility in processing.
Innovation Solution
A method using a sensor matrix and laser scanning device to monitor and control material removal along a breaking line, allowing for the determination of remaining wall thickness and position without requiring additional detection means, by comparing individual sensor measurements with reference values and interpolating positional deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a sensor array is used to monitor material removal along the breaking line, then the manufacturing precision of the breaking line is improved, but the device complexity increases
Solution Approach 1:
The patent replaces the mechanical positioning system with an optical measurement system. Instead of using complex mechanical alignment mechanisms to position sensors precisely, the invention uses a sensor array that detects the breaking line position optically through the workpiece, substituting mechanical precision requirements with optical detection capabilities.
Solution Approach 2:
The patent introduces an intermediary measurement system between the laser processing system and the workpiece. The sensor array acts as an intermediary that indirectly measures the breaking line position by detecting optical properties (transmission, reflection) of the workpiece material at the breaking line location, rather than directly measuring mechanical positions.
2Manufacturing precision
If precise positioning of the trim part relative to the sensor array is required, then the manufacturing precision is improved, but the ease of operation deteriorates
Solution Approach 1:
The patent implements a self-aligning measurement system where the sensor array automatically adapts to the workpiece position. The system uses optical feedback from the workpiece itself to determine the breaking line position, allowing the workpiece to 'define' its own measurement coordinates rather than requiring external alignment to a fixed sensor array.
Solution Approach 2:
The patent transforms the static, fixed-position sensor array into a dynamic measurement system that can adapt its measurement coordinates based on the actual workpiece position. The system dynamically adjusts its reference frame or interpretation of sensor signals to account for variations in workpiece placement, making the measurement process flexible rather than rigid.
3Measurement precision
If additional detection means are used to verify breaking line position, then the measurement precision is improved, but the device complexity increases
Solution Approach 1:
The patent makes the sensor array multi-functional by enabling it to perform both primary measurement functions (monitoring material removal, determining remaining wall thickness) and secondary verification functions (checking breaking line position and contour) using the same hardware components. The sensor array is designed to extract multiple types of information from the same optical signals.
Solution Approach 2:
The patent combines multiple measurement functions into a single integrated sensor array system. Instead of using separate detection devices for wall thickness measurement and position verification, the invention merges these functions into one sensor array that simultaneously performs both tasks by analyzing different aspects of the optical signals received from the workpiece.
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
Enables accurate monitoring of remaining wall thickness and verification of breaking line position with minimal computational effort, ensuring consistent quality and flexibility in processing without the need for precise initial alignment.
Implementation Method 1
a laser beam scanning across the vehicle interior trim part along the predetermined breaking line removes material until individual sensors of the sensor matrix detect a portion of the laser beam transmitting through the vehicle interior trim part
Implementation Method 2
individual sensors of the sensor matrix detect a portion of the laser beam transmitting through the vehicle interior trim part
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a method for producing a predetermined breaking line (2) in a vehicle interior trim part (1) using a scanning laser beam (S) and for testing it. Individual sensors of a sensor matrix (3) at each of the resulting holes in the predetermined breaking line (2) detect a transmitting portion of the laser beam (S) and generate individual measurement signals. At least some of these individual measurement signals are stored when a total reference signal is reached and compared with the individual reference values assigned to the processing locations. The contour and position of the produced predetermined breaking line (2) can be evaluated from this comparison.