A METHOD FOR PROCESSING ELEMENTS INTO FINAL ELEMENTS

Abstract

The present invention relates to method for cutting and shaping and/or bending a metal element into a final element using laser means, the method comprising providing data containing a final model of the final element and providing a set of instructions as to how to process the final element from the metal element, measure the processing and provide at least a second set of instructions based on feedback, such as geometrical measurements during said processing, so as to create a final element.

Claims

1. A method for cutting and at least one of shaping, welding and bending a metal element into a final element, the method comprising: providing a metal element to be processed into a final element by cutting and at least one of shaping, welding and bending the metal element, providing a laser configured to cut and at least one of shape, weld and bend the metal element, the laser comprising at least a first laser source, providing a measuring device configured to measure a position of one or more sections of the metal element being cut and at least one of shaped, welded and bent by the laser, providing a control configured to controlling the laser, wherein the controller is enabled to control at least a vector and velocity of the vector, an amount of energy and beam focus of the laser, providing data, the data comprising at least one of a final model of the final element and initial instructions as to how the metal element is to be processed into the final element by cutting and at least one of shaping, welding and bending the metal element with the laser, providing an input/output device configured to receive and send at least the data, providing a data processor configured to process the data from the input/output device to provide a first set of instructions to the controller, the instructions comprising at least a sequence of cutting and at least one of shaping, welding and bending and further providing calculations for the vector and velocity of the vector, the amount of energy and beam focus to perform a cutting process and at least one of a shaping, welding and bending process, by the laser, to one or more sections of the metal element being at least one of cut, shaped, welded and bent, and in which the data processor provide at least a secondary set of instructions to the controller, wherein the at least secondary set of instructions are calculated by the data processor based on measurements provided by the measuring device, and in which the laser cuts and at least one of shapes, welds and bends the metal element into the final element.

2-16. (canceled)

17. The method according to claim 1, further comprising: providing a fixation mechanism configured to fixate at least a first section of the metal element, the fixation mechanism being controlled by the controller, and fixating at least a first section of the metal element during the cutting process and at least one of the shaping, bending and welding process.

18. The method according to claim 1, further comprising: providing a fixation mechanism, wherein the fixation mechanism is adapted as a dynamic fixation device being controlled by the controller and the at least first and the secondary set of instructions further comprise instructions as to how the controller controls the dynamic fixation device, and fixating the metal element at various sections during the cutting process and at least one of the shaping, bending and welding process.

19. The method according to claim 1, the method further comprising: providing a conveyor belt, the conveyor belt being controlled by the controller, transporting one or more metal element(s) into a processing cell for processing the metal element into the final element, and transporting the final element out from the processing cell.

20. The method according to claim 1, the method further comprising: providing an automatic positioning mechanism being controlled by the controller and providing a fixation mechanism, the automatic positioning mechanism being adapted to position the metal element in the fixation mechanism and the at least first and second set of instructions further comprise instructions as to how the controller controls the automatic positioning mechanism, and repositioning the metal element in the fixation mechanism during cutting and at least one of the shaping, bending and welding of the metal element.

21. The method according to claim 1, the method further comprising: providing a temperature sensor, providing at least a first temperature measurement of a section of the metal element to the data processor for calculating the at least first and second set of instructions.

22. The method according to claim 1, the method further comprising: providing a gas exhaust being controlled by the controller and the at least first and second set of instructions further comprise instructions as to how the controller controls the gas exhaust, and providing gas to a section of the metal element being cut and at least one of shaped, bent and welded.

23. The method according to claim 1, the method further comprising: 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, performing at least one of cutting and shaping of the second section of the metal element to form at least a first protruding element of the second section of the metal element, performing at least one of shaping and bending the first or second section of the metal element to join or insert the first protruding element into or through the first hole.

24. The method according to claim 1 further comprising: 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, performing at least one of cutting and shaping of the second section of the metal element to form at least a first protruding element of the second section of the metal element, performing at least one of shaping and bending the first or second section of the metal element to join or insert the first protruding element into or through the at least first hole. welding the at least first protruding element to interlock with the at least first hole.

25. The method according to claim 1, the method further comprising: providing a second element to be processed with the metal element providing one or more fixation mechanisms, and the metal element and the second element are positioned in the fixation mechanism, or the first metal element is positioned in a first fixation mechanism and the second element are positioned in a second fixation mechanism, and the laser process the metal element and the second element into the final element.

26. The method according to claim 1 further comprising: providing an induction coil, the induction coil being controlled by the controller, and preheating at least a section of the metal element with the induction coil prior to or during the processing of the metal element into the final element by the laser.

27. The method according to claim 1, the method further comprising providing a surface analysis device, the surface analysis device being adapted to measure backscatter from one or more surfaces of the metal element.

28. The method according to claim 1, the method further comprising providing a laser scanner, the laser scanner being adapted to measure light reflected from one or more surfaces of the metal element.

29. A device configured to cut and at least one shaping and bending a metal element into a final element, the device comprising: a laser configured to cut and at least one of shape and bend the metal element, a measuring device configured to measure a position of one or more sections of the metal element being cut and at least one of shaped and bent by the laser, a controller configured to control the laser, wherein the controller can control at least a vector and velocity of the vector, an amount of energy and beam focus of the laser, an input/output device adapted to receive and send data, the data comprising at least a final model as to how the metal element is to be processed into the final element by cutting and at least one of shaping and bending, by the laser, a data processor adapted to process the data from the input/output device and wherein the data processor further calculate at least a first set of instructions to the controller, wherein the first set of instructions comprise at least a sequence of cutting and at least one of shaping and bending and further comprise calculations for the vector and velocity of the vector, the amount of energy and beam focus, to perform a cutting process and at least one of a shaping and bending process, by the laser, to one or more sections of the metal element being at least one of cut, shaped and bent, and in which the data processor provide at least a secondary set of instructions to the controller, the at least secondary set of instructions being calculated by the data processor based on measurements provided by the measuring device, and in which the device cuts and at least one of shapes and bends the metal element into the final element.

30. The device according to claim 29, the laser further being configured to weld sections of the metal element into the final element.

31. A computer program code adapted to enable a data processor to calculate at least a first set of instructions to a laser device, the laser device comprising at least a first laser, a controller and a measuring device, wherein the computer program code, when being executed by the data processor, is adapted for carrying out the method as set forth in claim 1.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0085] 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.

[0086] FIG. 1 is a trimetric view of a laser processing method, according an embodiment of the invention.

[0087] FIG. 2 is a trimetric view of a second laser processing method, according to an embodiment of the invention.

[0088] FIG. 3 is a section view of two different interlocking methods, according to an embodiment of the present invention.

[0089] FIG. 4 is a trimetric view of another laser processing method, according to an embodiment of the invention.

[0090] FIG. 5 is a section view of a third interlocking method, according to an embodiment of the present invention.

[0091] FIG. 6 is a top view of various examples of fixation structures cut from an element, according to an embodiment of the invention.

[0092] FIG. 7 is a surface analysis representation, according to an embodiment of the invention.

[0093] FIG. 8 is a flow-chart of a method embodiment, according to the invention.

DETAILED DESCRIPTION OF AN EMBODIMENT

[0094] FIG. 1 is a trimetric view of a laser processing method, according to an embodiment of the invention. Figure illustrates, from left top to right bottom, the process of manufacturing a final element 2, from a metal element 1. The final element 2 is manufactured by initially cutting two identical holes 10, 10′ in the metal element 1. Then two outlines 11, 11′ is cut around the two holes 10, 10′, creating two identical sections 12, 12′. A first part 20 of the first section 12 and a first part 20′ of the second section 12′ is bend upwards, from the plane of the metal element 1. Then, a second part 21 of the first section 12 and a second part 21′ of the second section 12′ is bend upwards, from the plane of the metal element 1, enabling the first part 20 of the first section 12 and the first part 20′ of the second section 12′ to abut, creating a gap line 30 between the two parts 20, 20′. Then the gap line 30 is welded, interlocking the first section 12 and the second section 12′, after which the final element 2 is cut from the non-processes section 3 of the metal element 1, to finalize the final element 2, wherein the two sections 12, 12′ are fixated by a weld 30′, creating a rigid three-dimensional structure from the two-dimensional metal element 1.

[0095] FIG. 2 is a trimetric view of a second laser processing method, according to an embodiment of the invention. The figure illustrates, four processing steps P1, P2, P3 and P4. The first process step P1 illustrates a cut-out 4 of a metal element 1, the cut-out 4 having a first and second cut hole 100, 100′ and two protruding elements 110, 110′. In the second process step P2, the figure further illustrates three sections SEC1, SEC2 and SEC3 of the cut-out 4. To form a final element 2, the third process step P3 illustrates that SEC3 is bend BEND1 relative to SEC 1 and SEC2, forming an element wherein SEC 3 has a plane perpendicular or substantially perpendicular to a plane of SEC1 and SEC2. In the fourth process step P4, SEC 2 is bend BEND2 relative to SEC1, forming the final element 2, wherein the plane of SEC2 is perpendicular or substantially perpendicular to the plane of SEC1, SEC3 abuts a surface of SEC 1 and the protruding elements 110, 110′ are protruding from the holes 100, 100′, respectively, so as to interlock SEC3 to SEC1. In an embodiment of the invention, further laser cutting, laser bending or laser welding processes can be performed on the final element.

[0096] FIG. 3 is a section view of two different interlocking methods, according to an embodiment of the invention. The figure illustrates two different methods IW, IB for interlocking three joint sections JS1, JS2 and JS3. The interlocking method for welding IW illustrates three sections, JS1, JS2 and JS3, wherein JS1 and JS2 are fixated (not shown) and JS3 protrudes in a gap suitable for laser welding JW, between the two joint sections JS1, JS2. In IW′ the three joint sections JS1, JS2 and JS3 has been laser welded W1 together so as to interlock the three joint sections JS1, JS2 and JS3. The interlocking method for bending IB illustrates three sections, JS1, JS2 and JS3, wherein JS1 and JS2 are fixated (not shown) and JS3 protrudes in a gap JB suitable for laser bending, between the two joint sections JS1, JS2. In IB′, JS3 has been bend B1 together, so as to interlock the three joint sections JS1, JS2 and JS3.

[0097] FIG. 4 is a trimetric view of another laser processing method, according to an embodiment of the invention. The figure illustrates, four processing steps P1, P2, P3 and P4. The first process step P1 illustrates a cut-out 4 of a metal element 1, the cut-out 4 having a first and second laser cut pattern 40, 40′ and two protruding elements 110, 110′. In the second process step P2, the figure further illustrates three sections SEC1, SEC2 and SEC3 of the cut-out 4 and two wing-shaped holes 50, 50′ formed from the two laser cut patterns 40, 40′. To form a final element 2, the third process step P3 illustrates that SEC3 is bend BEND1 relative to SEC 1 and SEC2, forming an element wherein SEC 3 has a plane perpendicular or substantially perpendicular to a plane of SEC1 and SEC2. In the fourth process step P4, SEC 2 is bend BEND2 relative to SEC1, forming the final element 2, wherein the plane of SEC2 is perpendicular or substantially perpendicular to the plane of SEC1, SEC3 abuts a surface of SEC 1 and the protruding elements 110, 110′ are protruding from the wing-shaped holes 50 and 50′, respectively, so as to interlock SEC3 to SEC1. In an embodiment of the invention, further laser cutting, laser bending or laser welding processes can be performed on the final element.

[0098] FIG. 5 is a section view of a third interlocking method, according to an embodiment of the present invention. The interlocking method for bending IB illustrates three sections, JS1, JS2 and JS3, wherein JS1, JS2 or JS3 are fixated (not shown) and JS3 protrudes in a gap JB suitable for laser bending, between the two joint sections JS1, JS2. In IB′, JS1 and JS2 have been bend B1, B2, abutting JS1 and JS2 to a portion of JS3, so as to interlock the three joint sections JS1, JS2 and JS3.

[0099] FIG. 6 is a top view of various examples of fixation structures cut from an element, according to an embodiment of the invention. The figure illustrates a metal element with a cut-out 4 and a plurality of fixation structures FS, cut from the metal element 1, so as to fixate the cut-out 4 to the metal element 1 during any further processes (not shown) performed to the cut-out 4.

[0100] 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.

[0101] In another embodiment of the invention, the metal element may be an element from another material than metal, such as a polymer.

[0102] FIG. 7 shows a metal element 1 being analyzed for any surface defects or contamination. The figure shows a square, flat metal element 1 wherein the surface has been analyzed for backscatter intensity, and wherein said surface has a first area SUR which has a uniform backscatter, a second area DEF which has a defect, such as scratch and a third area CONT which has been contaminated by a fingerprint.

[0103] 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.

[0104] FIG. 8 is a flow-chart of a method embodiment, according to the invention. The flow-chart is a method embodiment for manufacturing a final element from a metal element, using a plurality of laser processes, the method comprising: [0105] S1—providing a metal element to be processed into a final element by cutting and shaping and/or bending, [0106] S2—providing laser means for cutting and shaping and/or bending the metal element, said laser means comprising at least a first laser, [0107] S3—providing measuring means for measuring a position of one or more sections of the metal element being cut and shaped and/or bent by said laser means, [0108] S4—providing controlling means for controlling the laser means, in which the controlling means can control at least a vector and velocity of said vector, an amount of energy and beam focus of said laser means, [0109] S5—providing data, said data comprising at least a final model of the final element and/or initial instructions as to how the metal element is to be processed into said final element by cutting and shaping and/or bending the metal element with the laser means, [0110] S6—providing input/output means for receiving and sending at least said data, [0111] S7—providing data processing means for processing the data from the input/output means to provide a first set of instructions to the controlling means, said instructions comprising at least a sequence of cutting and shaping and/or bending and further providing calculations for the vector and velocity of said vector, the amount of energy and beam focus to perform a cutting and shaping and/or bending process, by the laser means, to one or more sections of the metal element being cut and/or shaped and/or bent, and [0112] S8—in which the data processing means provide at least a secondary set of instructions to the controlling means, the at least secondary set of instructions are calculated by the data processing means based on measurements provided by the measuring means, and in which the device cuts and shapes and/or bends the metal element into the final element.

[0113] 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).

[0114] 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.

[0115] 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.

[0116] 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.

[0117] 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.

[0118] 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.

[0119] 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.

[0120] 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.