Patent Application
20230266735
The present invention relates to a method and device for processing one or more elements into one or more final element from a computer model of the final element.
Processing of metal elements, such as sheet metal, into a final element is currently done by a performing a plurality of processes, such as laser cutting, grinding, bending, drilling, milling, polishing, engraving, marking, surface treating and forming the metal element, so as to create a final element which has undergone one or more of the above mentioned processes. When a metal element is subdued to one or more processes, the metal element is to be moved between a plurality of machines, such as a laser cutter, a milling machine and a bending machine. Having more machines in a shop requires more costs to maintain said machines and more operators, in order to have the required skills to set up and operate said machines, which further adds to costs and time consumption, to create a final element.
Furthermore, by moving an element, during processing, the tolerances of the final element can be inferior to a metal element being processed to a final element in a single machine, as a chain of tolerances build up during transfer between two or more processing machines.
Hence, an improved processing method and processing machine would be advantageous, and in particular a more efficient and/or reliable laser processing method and laser processing device would be advantageous.
It is a further object of the present invention to provide an alternative to the prior art.
In particular, it may be seen as an object of the present invention to provide a method and device for processing one or more metal elements, that solves the above mentioned problems of the prior art with using a plurality of machines for performing a plurality of processes to a metal element, in order to manufacture a final element, and instead provide a single machine to replace the plurality of processes with a laser processing method and device, which can perform all of the above processes, during a single set up of the metal element.
Thus, the above described object and several other objects are intended to be obtained in a first aspect of the invention by providing a method for cutting and shaping and/or bending a metal element into a final element, the method comprising:
The invention is particularly, but not exclusively, advantageous for obtaining a method for processing at least one metal element into one or more final elements using a single machine and thus, replacing a plurality of processing machines, such as, but not limited to, a bending or forming machine, a milling machine, a drilling machine, a grinding machine and a cutting machine. Using a single machine for performing all of the abovementioned processes saves time, is more efficient, increases the accuracy of the performed processes, reduces handling and storage of half-manufactured elements. It is to be understood that two or more final elements may be manufactured from one or more metal elements or one or more metal elements and elements from a material different from metal.
Furthermore, the invention is advantageous for forming, cutting and bending at least one metal element, so as to bend a section of the metal element towards a second section of the metal element and create a final element, e.g. a substantially square box, a rounded, donut shaped element, a rotor blade.
The invention is particularly advantageous for creating interlocked elements, such as by cutting a protruding element in a first section of the metal element, and cutting a corresponding hole in a second section of the metal element and bending the first or second section in order for the protruding element to abut to or be bent through the hole. For further interlocking the protruding element with the hole, the protruding element, when inserted through the hole, can be bent or welded on a backside of the second section of the metal element.
The metal element, according to the first aspect of the invention, may, instead, be a polymer element, a fiber element, a ceramic element or an alloy element. The final element may further be manufactured from two or more elements, such as a metal element and a polymer element, a fabric, wood or other non-laser processed elements. Furthermore, more final elements may be manufactured from one or more elements, according to the invention.
In the context of the present invention, shaping is to be understood as applying energy to a surface of a metal element so as to create or form e.g. a double curved, a convex or concave shape in said metal element, through heat expansion of said metal element. As an example, by applying energy to said element in a continuously calculated pattern, the invention can create a desired indentation or depression into a surface of said metal element. In another example, the invention can create a cone shape into or out from said metal element, by applying energy to a surface of said metal element, so as to manipulate certain sections of the surface of said metal element, through energy applied to certain points of said surface of said metal element.
In the context of the present invention, a metal element is to be understood as any element comprising metal, such as, but not limited to, iron, lead, gold, aluminum, platinum, uranium, zinc, lithium, sodium, tin, silver, copper, brass, titanium, magnesium, steel, a galvanized metal or any metal alloy. As an example, a metal element could be a block or plate of copper or a sheet metal, such as a steel sheet metal element.
In the context of the present invention, cutting is to be understood as cutting into a surface so as to create a surface groove or cutting through a surface and creating a through-going groove or cutting a metal element into a plurality of metal elements. As an example, laser ablation can be used to create a hole in a surface, which resembles the hole of a manual drilling process.
In the context of the present invention, bending is to be understood as bending a section of the metal element at an angle, relative to an adjacent section of said metal element, such as by bending a sheet metal into a 90 degrees angle.
In the context of the present invention, processing is to be understood as an operation or treatment performed to the element, such as a metal element, so as to manufacture or create an element different from the non-processed element, e.g. surface treating, color treatment, case-hardening, shaping, bending, forming, cutting or welding said metal element.
This embodiment of the invention is particularly advantageous for creating a wear-resistant or weather-resistant surface of a final element, after a shaping, bending, forming or welding process.
In the context of the present invention, laser means is to be understood as means for generating a beam of coherent electromagnetic radiation usually in the ultraviolet, visible, or infrared regions of the spectrum, such as, but not limited to a fiber laser, a CO2 laser, pulsed-rod laser, a solid-state laser, a disc laser, a diode laser or a UV laser or a combination of one or more of the mentioned laser types, such as laser means comprising a CO2 laser and a fiber laser. A laser comprises an energy source which is directed from the laser to a point of interest and in the context of the present invention, a vector is to be understood as the direction from which the laser origins, to a point at which the laser interacts with the metal element, which defines a directed line segment between the laser and the metal element.
In another embodiment of the invention, the device may further comprise a combination of laser means and another source of energy, such as an electron beam.
In the context of the present invention, beam focus is to be understood as the width and shape of the laser beam at the point of interaction with the metal element, such as, but not limited to a circular beam with a diameter of between 10.00 cm and 0.0005 cm, more preferably between 5.00 cm and 0.005 cm and most preferably between 3.00 cm and 0.01 cm. Other beam shapes may be, but not limited to oval, square or any tailored beam patterns consisting of one or more tailored beam patterns of one or more spots.
In the context of the present invention, measuring means is to be understood as means for measuring one or more geometries, densities and features of the metal element, e.g. a line scanner, a 3D scanner or 3D measuring device, an ultrasound device, stereo vision, an X-ray device, time of flight, a scattered light/structured light sensor, a 2D scanner, 1D scanner/point sensor, a CCD sensor system or a tactile measuring system.
In the context of the present invention, controlling means is to be understood as a device or mechanism used to regulate or guide the operation and/or connection to a peripheral device, such as, but not limited to, the laser means and the measuring means, the controlling means being e.g. a computer, a chip, or a circuit.
In the context of the present invention, data is to be understood as a list of instructions or file containing technical drawings, such as a CAD file of an element, to be interpreted by a computer or a combination of supplied data and measurement data obtained by measuring a prototype or from data supplied from a database.
In the context of the present invention, input/output means is to be understood as a computer, processing system or device arranged to send and receive information from or to a data processing system or computer, such as a wireless receiver/transmitter or a physical data port.
In an embodiment of the invention, the input means may be a screen associated with the device, enabling an operator to directly input instructions, as to how the device is to process the metal element into the final model.
In another embodiment of the invention, the input means may be a USB port or other data port, for receiving data from a device containing data.
In the context of the present invention, a sequence is to be understood as a continuous or connected series of processes. As an example, a sequence may comprise a cutting process, a bending process and a welding process in that order.
In the context of the present invention, data processing means is to be understood as a computer, a chip or a circuit being arranged for calculating and/or interpreting data from a peripheral device, such as calculating a defined energy to be applied by a fiber laser to a metal element to perform a desired action, such as cutting and, optionally, recalculating said applied energy through a feedback loop, from the measuring means, a temperature sensor, a distance sensor, a light sensor, an absorption sensor, a radiation sensor, such as a passive or active infrared sensor or other sensor.
In an embodiment of the present invention, the data processing means provide continuous instructions, based on a first set of instruction and a plurality of subsequent sets of instructions, said plurality of subsequent instructions being based on one or more inputs from e.g. the measuring means. This embodiment is particularly advantageous for providing accurate laser processing through accurate information relating to the current geometry, of any sections of the metal element, being processed.
In an embodiment of the invention, the method further comprises welding means controlled by the controlling means and the at least first and second set of instructions further comprise instructions as to how the controlling means controls said welding means, in which the embodiment is arranged to weld two or more sections of the metal element together.
This embodiment of the invention is particularly advantageous for interlocking two or more sections of the metal element together by welding, such as welding along or in a point, between two abutting edges of said two sections of the metal element.
In another embodiment of the invention, the method further comprises laser means according to the first aspect of the invention, in which the laser means comprises welding means.
This embodiment of the invention is particularly advantageous for using a method of creating a final element, in which the laser means performs all of the processing means, so as to increase the accuracy of said performed processes.
In another embodiment of the invention, the method further comprises fixation means for fixating at least a first section of the metal element, said fixation means being controlled by the controlling means, and in which the fixation means fixate at least a first section of the metal element during the cutting and shaping and/or bending and/or welding process.
This embodiment is advantageous for fixating elements, which may move during the processing and hence, reduce the accuracy of said processes.
In a preferred embodiment of the invention, the method further comprises dynamic fixation means being controlled by the controlling means and the at least first and second set of instructions further comprise instructions as to how the controlling means controls said dynamic fixation means, and wherein the method according to the first aspect further comprises fixating the metal element at various sections during the cutting and shaping and/or bending and/or welding process. The dynamic fixation means may comprise a robotic gripper, or other suitable robotic mechanism.
This embodiment is particularly advantageous for moving the element during processing, so as to enable the laser processing means to have access to additional angles of the metal element during processing. As an example, the metal element can be processed on one or more sections and surfaces, which have been facing away from the laser means, such as towards a bench or table, during initial processing.
In another embodiment of the invention, the method further comprises a conveyor belt, said conveyor belt being controlled by the controlling means, the method further comprising transporting one or more metal element into a processing cell for processing the metal element into the final element, and optionally transporting the final element out from the processing cell.
This embodiment is particularly advantageous for processing a plurality of elements, which are fed through a laser cell, so as to mass-produce a type of final element, saving time and reducing cost of the final elements. In other embodiments of the invention the transport mechanism for transporting an element into the processing cell may be a set of rollers, carts, wagons or coasters, suitable for transporting elements along a predetermined path.
In another embodiment of the invention, the method further comprises automatic positioning means being controlled by the controlling means for positioning the metal element in the fixation means and the at least first and second set of instructions further comprise instructions as to how the controlling means controls said automatic positioning means, and wherein said metal element is repositioned in the fixation means during the cutting and shaping and/or bending and/or welding of said metal element.
This embodiment is particularly advantageous for creating complex final elements, which otherwise would provide shadowing of one or more sections of the metal element relative to the vector of the laser means. By adjusting the metal element with the automatic positioning means, the laser means has better access to a plurality of section of the metal element. As an example, the automatic positioning means may be a robotic arm with a gripping device, for gripping the metal element.
In another embodiment of the invention, the method further comprises a temperature sensor, wherein said temperature sensor provides at least a first temperature measurement of a section of the metal element to the data processing means for calculating said at least first and second set of instructions. This embodiment is advantageous for quality assurance and control, so as to ensure that the metal element is not overheated during processing, which may alter the surface, elastic and strength properties of the metal element and prevent unwanted geometries in the element, such as buckling. In another embodiment of the inventions, the sensor may be a sensor suitable for measuring radiation, such as an infrared sensor or camera.
In the context of the present invention, buckling is to be understood as buckling is the sudden change in shape of a structural component during processing, such as during shaping/forming or bending.
In an advantageous embodiment of the invention, the method further comprises providing a gas exhaust being controlled by the controlling means and the at least first and second set of instructions further comprise instructions as to how the controlling means controls said gas exhaust, and the method further comprises providing gas to a section of the metal element being cut and shaped and/or bent and/or welded.
This embodiment is advantageous for ensuring quality assurance, in which the provided gas ensures improved cutting, forming and welding of the metal element and further provides oxidative protection to the element.
This embodiment may further be advantageous for correcting the temperature of the point of processing, by adjusting flow and temperature of the gas supplied. In another advantageous embodiment, the data relating to the gas may be provided to the processing means for further optimizing the cutting, bending, shaping/forming and welding processes.
In another embodiment of the invention, the method further comprises cutting at least a first and second section in the metal element, cutting at least a first hole in the first section of the metal element, cutting and/or shaping the second section of the metal element to form at least a first protruding element of said second section of the metal element, shaping and/or bending the first or second section of the metal element to join or insert the first protruding element into or through said first hole.
This embodiment of the invention is advantageous for planning and designing interlocking sections of the metal element, so as to improve the stability and rigidity of the final model.
In an advantageous embodiment of the invention, the method further comprises shaping and/or bending and/or welding the at least first protruding element to interlock with the at least first hole.
This embodiment of the invention is advantageous for planning and designing interlocking sections of the metal element, so as to improve the stability and rigidity of the final model.
In an embodiment of the invention, the metal element is a sheet metal, a metal plate, a metal foil, a slab or block of metal or a metal tube.
In an advantageous embodiment of the invention, the method further comprises providing a second element to be processed with the metal element, providing one or more fixation means, and wherein the metal element and the second element are positioned in the fixation means or the first metal element is positioned in a first fixation means and the second element are positioned in a second fixation means and the laser means process the metal element and the second element into the final element.
This embodiment of the invention is advantageous for processing two or more metal elements to be processed, so as to create more complex final models. In an example of the embodiment, the second element is a polymer, such as, but not limited to PTFA, which is adjoined with the metal element. In another example of the embodiment of the invention, the second element is a second metal element, the metal of the second metal element being different from the metal of the first metal element.
In another advantageous embodiment of the invention, the method further comprises providing induction means, said induction means being controlled by the controlling means, and preheating at least a section of the metal element with the induction means before or during the processing of the metal element into the final element.
This embodiment is advantageous for saving time during the processing of the metal element.
In yet another advantageous embodiment of the invention, the method further comprises
In the context of the present invention, backscatter is to be understood as any deviation from expected light being reflected back in the direction from which it came, such as an expected reflection from a metal surface and wherein said backscatter may be converted into a map of the surface, said map comprising reflective information relating to all relevant areas of said surface. In other embodiments, the surface may comprise one or more of ceramics, paint or coatings, natural materials, such as wood or paper.
In an embodiment, a laser scanner may be used to measure the backscatter intensity from the laser line. As colors are a representation of the light, that is reflected from the surface in a given wavelength. The reflected wavelengths may be used to obtain an indication of the color of the scanned surface. However, in this case, the purpose is not to obtain the color of the surface, but to locally estimate the amount of absorbed and reflected light from the surface. The result can be represented as an image or map of the scanned surface, where the greyscale pixel intensities in an image corresponds to the amount of absorbed and reflected light. The shinier the surface, the more light is reflected and the brighter the surface will appear in the image.
When analyzing the surface, the wavelength of the laser light, used for scanning, should be close to the same wavelength as the laser used for processing, due to some surfaces reflecting different wavelengths of light. The same applies for the angle at which the laser is projected and subsequently captured on the surface, as this will also influence the result.
This embodiment of the invention, is particularly advantageous for analyzing the surfaces of the metal element, so as to correct or adjust for any surface defects or any contaminations, so as to ensure that the energy from the laser device, intended for processing said metal element is not scattered or reflected from the surface, and hence create instructions and/or process steps which correct for said surface defects or contaminations.
In the context of the present invention, defects or surface defects is to be understood as, but not limited to dents, scratches, protrusions, notches, cracks, cuts, wear, corrosion, etching, tarnish, fading, peel off or flake off and crevices or other not desired damages to the surface.
In the context of the present invention, contaminations is to be understood as, but not limited to oil, grease, hairs, dust, dirt, extraction, spillage, soot, moisture, process remains or other polluting particles present on a surface or impurities within said surface.
In a further embodiment, the surface analysis can be combined with a geometrical analysis of the metal element, such as a 2-D or 3-D geometrical analysis.
In yet another embodiment, the surface analysis may be used to preprocess any surfaces which may have defects or contamination.
The measuring means and the surface analysis means may be a single device, configured to provide geometrical data and surface data relating to the metal element and providing said data for processing of the metal element by using the laser supplied from the laser means intended for processing of the (metal) element, wherein the surface analysis is performed by using low power level settings on said laser means and a sensor for measuring the reflected backscatter.
In a second aspect, the present invention relates to a device for cutting and shaping and/or bending a metal element into a final element, the device comprising:
The device may especially be a laser processing device which is adapted for carrying out the method as set forth in the first aspect of the invention, such as to process a metal coil, a sheet metal or a block of metal into a final model, such as a complex final model which requires a plurality of processes to be finalized. This embodiment is advantageous for reducing the floor space required and time consumed and further to increase the accuracy of said processes, by completing all of said processes within a single device.
In a third aspect, the invention relates to a computer program for calculating at least a first set of instructions to the device according to the second aspect of the invention, when being executed by a data processor, in which the invention is adapted for controlling and/or for carrying out the method as set forth in the first aspect of the invention.
This embodiment is advantageous for providing a computer program product, which may be adapted to an existing laser processing device, so as to increase the processing features of said existing laser device.
In a fourth aspect, the invention relates to the use of a device according to the second aspect of the invention, for processing a metal element into a final element using any of the method disclosed in the first aspect of the invention.
The first, second, third and fourth aspect of the present invention may each be combined with any of the other aspects. These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments described hereinafter.
The method for cutting and shaping and/or bending a metal element, and a device for completing said method, according to the invention will now be described in more detail with regard to the accompanying figures. The figures show one way of implementing the present invention and is not to be construed as being limiting to other possible embodiments falling within the scope of the attached claim set.
In the context of the present invention, it is to be understood that simple and flexible strategies for constraining the part during forming is crucial for the laser forming process i.e. a stable position in space is mandatory for the process to work however, over constraining the part will hinder the desired deformation of the part. This problem is addressed by introducing flexible constraint elements FS3, FS6, FS8 i.e. stiff elements FS1, FS2, FS4, FS7, extendable elements FS5 etc. these elements are realised using the base material. The flexible elements can be designed for suppressing undesired deformation modes e.g. torsion, or alternatively allowing a desired deformation mode e.g. in-plane draw-in. This allows the part to form in the desired way and the position and stability of the part is kept, in order to have a stable fixation for the laser processing. The fixation points can if necessary gradually be disconnected by laser cutting, in order for the parts to form in the desired way. At the end of processing, the flexible structures may be disconnected from the fixture. Advanced fixation structures can also be applied, where more degrees of freedom are released gradually during forming/manufacturing of the final element from the metal element.
In another embodiment of the invention, the metal element may be an element from another material than metal, such as a polymer.
In an embodiment of the invention, the method corrects for said detected surface defects DEF and contaminations CONT, by adjusting the energy level for the laser device/means on said affected areas DEF, CONT, so as to attain the desired process of the metal element 1 in spite of said defect and/or contaminated areas DEF, CONT.
It is to be understood that continuous or intermittent subsequent sets of instructions can be created by repeating S3, S5 and S7 after performing S8 (a feedback loop).
In an embodiment of the invention, one or more laser processes can be carried out in the same unit to process sheet metal into a product/given component, said laser processes being: laser cutting (remote and/or gas assisted), laser forming/bending (laser induced bending/shaping), such as linear sharp and soft bends and doubly curved three dimensional bends, and laser welding.
With a combination of these processes, 3D structures in the form of a product/given component can be created directly from flat sheet metal. As an example: A piece of sheet metal is inserted into the machine. The piece is laser cut with gas assisted cutting to maximize speed and quality. Afterwards the piece is laser formed/bended, laser welded and laser cut remote and/or gas assisted in a defined sequence in order to shape the desired geometry. I order to achieve the geometry a number of measurement tasks are used to keep the tolerances.
By utilizing a combined laser system the desired processing can be done without any additional tooling or fixtures, and at a high pace with high surface quality, which decreases costs of creating a large variety of components from sheet metal, such as casings, mounting structures, blades, medical parts, component for architect designed buildings, prototypes, small batch sizes parts etc.
Another advantage of this invented system is the prospect of retrofitting existing laser systems with the technology, increasing the area of usage of an expensive machine.
In an advantageous embodiment of the invention, the feedback control of the laser forming process relates to continuous monitoring of the laser forming processes for deviations from the desired part geometry and handling of the possible errors by automatic adjustment of the initial plan of combined laser processing.
The control strategy is based on a feedback system where heat input trajectories are calculated based on either strain fields or curvature. The strain field or curvature is updated a number of times during the forming operation, by scanning the part and calculate a strain field or curvature mapping the current geometry to the final geometry.
Although the present invention has been described in connection with the specified embodiments, it should not be construed as being in any way limited to the presented examples. The scope of the present invention is set out by the accompanying claim set. In the context of the claims, the terms “comprising” or “comprises” do not exclude other possible elements or steps. Also, the mentioning of references such as “a” or “an” etc. should not be construed as excluding a plurality. The use of reference signs in the claims with respect to elements indicated in the figures shall also not be construed as limiting the scope of the invention. Furthermore, individual features mentioned in different claims, may possibly be advantageously combined, and the mentioning of these features in different claims does not exclude that a combination of features is not possible and advantageous.
| Number | Date | Country | Kind |
|---|---|---|---|
| PA 2020 70453 | Jul 2020 | DK | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/DK2021/050222 | 7/2/2021 | WO |
