Integrated Threaded Insert Application in Tube Laser Cutting
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Solution Overview
Problem
Existing machines for laser cutting of tubes and profiled sections require manual or offline insertion of threaded inserts, leading to prolonged production times due to the need for manual handling of workpieces.
Innovation Solution
An automated system integrated into the machine for laser cutting, which includes a working head, a carriage, and an automatic insert application system with a riveter and proximity sensor to place threaded inserts into pre-formed housings, allowing for coordinated and precise insertion of inserts during the cutting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual or offline insertion of threaded inserts is used, then the machine structure remains simple, but production time increases significantly
Solution Approach 1:
The patent combines the laser working head and the threaded insert application system into a single integrated machine. The insert application system is mounted on the same carriage as the laser head, allowing both operations to be performed on the workpiece without manual intervention. This merging of functions eliminates the need for separate offline operations while maintaining a relatively compact machine structure.
Solution Approach 2:
The system performs preliminary actions by forming the housing in the workpiece wall using the laser beam before applying the threaded insert. The housing formation is done automatically as part of the same machining cycle, preparing the workpiece in advance for insert installation without requiring separate manual steps.
2Productivity
If manual handling of workpieces is required for insert insertion, then the machine operation is simple, but production efficiency decreases
Solution Approach 1:
The machine performs the insert application operation automatically without requiring manual handling of workpieces. The carriage carries both the laser head and the insert application system, which automatically positions and installs inserts on workpieces during the machining cycle. This self-service capability eliminates manual intervention while maintaining operational simplicity through automated control.
3Loss of time
If an automatic insert application system is integrated into the machine, then production time is reduced, but the device complexity increases
Solution Approach 1:
The patent merges the insert application system with the existing laser machining carriage, sharing common structural elements and control systems. The riveter and insert supply assembly are mounted on the carriage, utilizing the same movement and positioning infrastructure already present in the laser machine, thereby minimizing additional complexity.
Solution Approach 2:
The carriage serves multiple functions: it carries the laser working head for machining operations and simultaneously carries the riveter for insert application. This multi-functionality allows the same mechanical infrastructure to perform both laser processing and insert installation, reducing the need for separate dedicated systems.
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 solution enables the efficient and automated insertion of threaded inserts of various sizes directly into laser-cut tubes and profiled sections, reducing production time and producing finished workpieces ready for use without additional reworking.
Implementation Method 1
forming a housing in the tube or profiled section by means of said working head
Implementation Method 2
a proximity sensor configured to detect the presence of the threaded insert in the insert picking seat
Data Source
AI summary
A method for operating a machine for laser cutting of tubes and profiled sections is provided. The machine has a working head having a focusing device adapted to focus a laser beam on the surface of the tube or profiled section to be worked, a carriage on which the working head is mounted, and an automatic insert application system for placing a threaded insert in a housing formed in a wall of the tube or profiled section by the laser beam. The automatic insert application system is integrated into the machine and configured to operate in a coordinated manner with the working head.