METHOD AND DEVICE FOR LASER CUTTING A SHEET METAL BLANK FROM A CONTINUOUSLY CONVEYED SHEET METAL STRIP

Abstract

The invention relates to a method for cutting a sheet metal blank from a sheet metal strip (1) continuously conveyed in a transport direction (T), by means of at least one laser cutting device (3), having the following steps: providing a laser cutting device (3) with at least one laser cutting head (5) which has a cutting nozzle (7) and which can be moved along a cutting path (S1, S2, S1′, S2′) specified so as to correspond to the geometry of the sheet metal blank by means of a controller (6), incrementally measuring the distance between the cutting nozzle (7) and the surface of the sheet metal strip (1) at at least one radially outer position (P.sub.1, P.sub.2) relative to the cutting nozzle (7) by means of a first distance measuring device (8), controlling the movement of the laser cutting head such that the first distance measuring device (8, 9) constantly remains overlapping the sheet metal strip (1), into a second position, in which the cutting nozzle is overlapping the sheet metal strip (1), wherein the height of the cutting nozzle (7) relative to the surface of the sheet metal strip (1) is regulated using the first distance values supplied by the first distance measuring device (8, 9) when the cutting nozzle (7) is moved from the first position in the direction of the second position.

Claims

1. A method for cutting a sheet metal blank from a sheet metal strip continuously conveyed in a transport direction via at least one laser cutting device, the method comprising: providing a laser cutting device with at least one laser cutting head having a cutting nozzle, which can be moved via a control unit along a predetermined cutting path corresponding to the geometry of the sheet metal blank; cyclic measurement of a distance between the cutting nozzle and a surface of the sheet metal strip at at least one radially outer position with respect to the cutting nozzle via a first distance measuring device; controlling a movement of the laser cutting head in such a way that, when the cutting nozzle is not in overlap with the sheet metal strip, the first distance measuring device always remains in overlap with the sheet metal strip; wherein the first distance measuring device comprises one of (i) and (ii) below: (i) comprises only one distance sensor attached to a rotatable cutting nozzle, wherein the distance sensor is rotated to a position in which it remains in overlap with the sheet metal strip when the cutting nozzle is not in overlap with the sheet metal strip; and (ii) comprises several distance sensors for measuring the distance between the cutting nozzle and the surface of the sheet metal strip at several different positions which are radially outside the cutting nozzle, wherein the distance between the cutting nozzle and the surface of the sheet metal strip is measured at a plurality of different positions which are radially outwardly located with respect to the cutting nozzle via the first distance measurement device; moving the cutting nozzle from a first position not in overlap with the sheet metal strip to a second position in overlap with the sheet metal strip, wherein a height of the cutting nozzle with respect to the surface of the sheet metal strip is controlled using the first distance values provided by the first distance measuring means when the cutting nozzle is moved from the first position towards the second position; and wherein at least a section of the cutting path starts at the edge of the sheet metal strip or of an aperture located in the sheet metal strip and runs to the interior of the sheet metal strip, wherein when the cutting nozzle is moved from the first to the second position, a laser beam emerging through the cutting nozzle is generated.

2. The method according to claim 1, wherein the generation of a laser beam emerging through the cutting nozzle during cutting operation is temporarily interrupted when the cutting nozzle is not in overlap with the sheet metal strip.

3. The method according to claim 1, wherein cutting parameters for generating the laser beam are changed when the cutting nozzle is in the first position.

4. The method according to claim 1, wherein the cutting nozzle is part of a second distance measuring device and a second distance value is measured via the second distance measuring device.

5. The method according to claim 1, wherein the first and/or the second distance values are used to control the distance between the cutting nozzle and the surface of the sheet metal strip.

6. The method according to claim 1, wherein a movement of the laser cutting head occurring from the second position to the first position is stopped when one of the two distance values or a difference between the two distance values is greater than a predetermined limit value.

7. The method according to claim 1, wherein capacitive or optical distance measuring devices are used in each case for measuring the first and/or second distance values.

8. An apparatus for cutting a sheet metal blank from a sheet metal strip continuously conveyed in a transport direction, the apparatus comprising: a transport device for continuously transporting a sheet metal strip in a transport direction; at least one laser cutting device having at least one laser cutting head which has a cutting nozzle and is held on a gantry such that it can be moved back and forth in the transport direction and in a y-direction running perpendicular to the transport direction; a control unit for moving the laser cutting head along a cutting path corresponding to the geometry of the sheet metal blank; a first distance measuring device for cyclically measuring a distance between the cutting nozzle and a surface of the sheet metal strip at at least one radially outer position with respect to the cutting nozzle; a control for regulating the distance between the cutting nozzle and a surface of the sheet metal strip; wherein a movement of the laser cutting head can be controlled via the control unit in such a way that, when the cutting nozzle is not in overlap with the sheet metal strip, the first distance measuring device always remains in overlap with the sheet metal strip; wherein the first distance measuring device comprises one of (i) and (ii) below: (i) comprises only one distance sensor attached to a rotatable cutting nozzle, so that the distance sensor can be rotated in each case to a position in which it remains in overlap with the sheet metal strip, when the cutting nozzle is not in overlap with the sheet metal strip; and (ii) comprises a plurality of distance sensors for measuring the distance between the cutting nozzle and the surface of the sheet metal strip at a plurality of different positions located radially outwardly with respect to the cutting nozzle; wherein via the control a height of the cutting nozzle with respect to the surface of the sheet metal strip is controlled using the first distance values provided by the first distance measuring device when the cutting nozzle is moved from a first position which is not in overlap with the sheet metal strip towards a second position which is in overlap with the sheet metal strip; wherein at least a section of the cutting path starts at the edge of the sheet metal strip or of an opening located in the sheet metal strip and runs to the interior of the sheet metal strip; and wherein the control is adapted to generate a laser beam exiting through the cutting nozzle when the cutting nozzle is moved from the first to the second position.

9. The apparatus according to claim 8, wherein the control unit is adapted to temporarily interrupt generation of a laser beam exiting through the cutting nozzle in cutting operation when the cutting nozzle is in the first position.

10. The apparatus according to claim 8, wherein the control unit is adapted to change cutting parameters for generating the laser beam when the cutting nozzle is in the first position.

11. The apparatus according to claim 8, wherein the cutting nozzle is part of a second distance measuring device for measuring second distance values.

12. The apparatus according to claim 8, wherein the control unit is adapted to control the distance between the cutting nozzle and the surface of the sheet metal strip via at least one of the first and second distance values.

13. The apparatus according to claim 8, wherein the control unit is arranged to stop a movement of the laser cutting head occurring from the strip interior across a strip edge when one of the two distance values or a difference between the two distance values is greater than a predetermined limit value.

14. The apparatus according to claim 8, wherein at least one of the first and second distance measuring devices are at least one of capacitive and optical distance measuring devices.

15-20. (canceled)

Description

[0027] The method and apparatus are explained in more detail below with reference to the drawings. They show:

[0028] FIG. 1 a schematic top view of a device for cutting sheet metal blanks,

[0029] FIG. 2 a schematic side view of a laser cutting head,

[0030] FIG. 3 a schematic sectional view according to section line A-A′ in FIG. 2,

[0031] FIG. 4 another schematic sectional view through a laser cutting head,

[0032] FIG. 5 a top view of a sheet metal strip section with cutting and traversing paths and

[0033] FIG. 6 a top view of a sheet metal strip section with alternative cutting and travel paths.

[0034] xx

[0035] In FIG. 1, a sheet metal strip 1 is guided by a transport device 2. The transport device 2 can be, for example, a roll straightening machine. Reference sign 3 generally denotes a laser cutting device in which a laser cutting head 5 is attached to a gantry 4. The laser cutting head 5 is movable in and against a transport direction T as well as in and against a y-direction y extending perpendicular to the transport direction T. Furthermore, the laser cutting head 5 is movable in a z-direction perpendicular to the y-direction and the transport direction T, so that a distance between the laser cutting head 5 and a surface of the sheet metal strip 1 is variable.

[0036] The reference sign 6 designates a control unit which is connected in particular to the gantry 4 for the exchange of signals. By means of the control unit 6, the gantry 4 can be controlled in such a way that the laser cutting head 5 is guided along a predetermined cutting path corresponding to the geometry of a sheet metal blank to be produced. Furthermore, the control unit 6 can be used to control a distance between the laser cutting head 5 and a surface of the sheet metal strip 1. —Several laser cutting heads 5 can also be movably mounted on the gantry 4.

[0037] FIG. 2 shows a schematic side view of the laser cutting head 5. A cutting nozzle 7 of the laser cutting head 5 is used to discharge cutting gas. Furthermore, a laser beam L exits through the cutting nozzle 7. An axis of the cutting nozzle 7 approximately congruent with the laser beam is designated with the reference sign A. A first distance sensor 8 of a first distance measuring device is mounted at a first radially outer position P.sub.1 of the cutting nozzle 7. A second distance sensor 9, which is also part of the first distance measuring device, is expediently mounted at a second radially outer position P.sub.2. The distance sensors 8, 9 can be capacitive or optical distance sensors. In the embodiment examples shown in FIG. 2, the first distance measuring device 8 and the second distance measuring device 9 are arranged at approximately the same radial distance with respect to the axis A. However, it is also possible that the first 8 and the second distance measuring device 9 are arranged at a different radial distance with respect to the axis A.

[0038] The reference sign 10 designates a further distance sensor of a second distance measuring device, which directly surrounds the cutting nozzle 7 in the radial direction. The further distance sensor 10 is therefore provided at a radially inner position with respect to the cutting nozzle 7.

[0039] A circumferential edge of the cutting nozzle 7 is designated by the reference sign U. A “radially outer position” in the sense of the present invention is present if the respective distance sensor 8, 9 of the first distance measuring device is arranged at a distance of at least 2 mm, preferably at least 5 mm, particularly preferably at least 10 mm from the circumferential edge U or an outer circumferential surface of the cutting nozzle 7.

[0040] The controller unit 6, which may be a computer, is provided with a comparison device 11 and a control device 12. The comparison device 11 and the control device 12 can be correspondingly prepared program sections of the control unit 6. The reference sign 13 designates an actuator which is coupled to the control device 12. By means of the actuator 13, the laser cutting head 5 or the cutting nozzle 7 can be raised and lowered in the z-direction. The reference sign 14 designates a signal line via which the measured values measured by the distance measuring devices are transmitted to the control unit 6.

[0041] The function of the device is as follows:

[0042] By means of the control unit 6, drive devices (not shown here) on the gantry 4 are controlled in such a way that the laser cutting head 5 is moved along a predetermined cutting path over the sheet metal strip 1, which is continuously moved in the transport direction T. The laser cutting head 5 is then moved along the sheet metal strip 1. During the movement of the laser cutting head 5, the respective first distances to the surface of the sheet metal strip 1 are measured cyclically or quasi-continuously by means of the first distance measuring device. The corresponding first distance values are transmitted to the control unit 6 via the signal line 14. The first distance values are compared by means of the comparison device 11. As soon as one of the two distance values exceeds a predetermined limit value or a difference between the distance values lies outside a predetermined limit value, a switch-off signal is generated and transmitted to the control unit 6. As a result, the movement of the laser cutting head 5 is stopped, in such a way that one of the first distance sensors 8, 9 remains in overlap with the sheet metal strip 1. With the distance sensor 8, 9 in overlap with the sheet metal strip 1, the distance of the laser cutting nozzle 7 to the sheet metal strip can continuously to be kept within a predetermined range. Thus, different from the prior art, it is no longer necessary to raise the laser cutting head 5 before passing over the edge of the strip. Apart from this, it is possible to move the laser cutting head 5 by means of the control unit 6 along a next cutting path which runs from the strip edge towards the interior of the sheet metal strip. The now possible guidance of a cutting path from the strip edge towards the inside of the sheet metal strip creates new freedom in the cutting strategy. Cutting paths can be changed and traverse paths shortened. This means that the time required to produce a sheet blank can be reduced.

[0043] As can be seen further from FIG. 2, the movement of the laser cutting head 5 is expediently stopped in such a way that one of the distance sensors 8, 9 and the axis A of the cutting nozzle 7 no longer cover the sheet metal strip 1, but the other distance sensor 9 covers the sheet metal strip 1.

[0044] In the embodiment example shown in FIG. 2, two first distance sensors 8, 9 are provided. Of course, it is also possible that a device in which only a first distance sensor is provided is used to carry out the method according to the invention. In this case, the cutting nozzle 7 is preferably rotatable so that the first distance sensor 8 attached thereto can be rotated in each case to a position in which it remains in overlap with the sheet metal strip when the cutting nozzle is not in overlap with the sheet metal strip.

[0045] In a particularly simple embodiment, it is also possible to omit the further distance sensor 10 shown in FIG. 2. I.e., the method according to the invention can also be carried out with a single first distance sensor 8, which is mounted in a radially outer position P1 of the cutting nozzle 7. —In this case, a movement of the laser cutting head is controlled by means of the control unit in such a way that the first distance sensor 8, as a component of the first distance measuring device, always remains in overlap with the sheet metal strip. By means of the first distance measuring device, the distance between the cutting nozzle 7 and the surface of the sheet metal strip is measured cyclically or quasi-continuously. A distance between the cutting nozzle 7 and the surface of the sheet metal strip is controlled on the basis of the first distance values supplied by the first distance measuring device. Provided that the cutting nozzle 7 is located at a first position that is not in overlap with the sheet metal strip, the height of the cutting nozzle 7 with respect to the surface of the sheet metal strip is further controlled using the first distance values provided by the first distance measuring device when the cutting nozzle 7 is moved from the first position toward the second position.

[0046] FIG. 3 shows a section according to section line A-A′ in FIG. 2. For reliable detection of the strip edge or any recesses in the sheet metal strip 1, several first distance sensors, for example 3, 4, 5, 6 or more, may be fitted in radially outer positions P.sub.1, P.sub.2, . . . P.sub.n. FIG. 4 shows a cutting nozzle 7 in which further first distance sensors 15a, 15b, 15c, 15d, 15e and 15f are mounted in radially outer positions. This makes it possible to detect the distance of the entire radial environment of the cutting nozzle 7. This further increases process reliability.

[0047] FIG. 5 shows a top view of a sheet metal strip 1, in which first cutting paths S1 of a first laser cutting head and second cutting paths S2 of a second laser cutting head are each guided starting from the strip interior I of the sheet metal strip 1 and to the strip edge K. To produce the sheet metal blank, the first laser cutting head is first moved over the first puncture point E1. Then, starting from the first puncture point E1, the first laser cutting head is moved along the first cutting path S1 to the strip edge K. As soon as the first laser cutting head is outside a collision area, a second laser cutting head is moved to the first puncture point E1. The second laser cutting head is moved along the second cutting path S2 towards the strip edge K.

[0048] To produce the further first cutting path S1′, the first laser cutting head is moved to the second puncture point E2. Subsequently, the first laser cutting head is moved from the second puncture point E2 along the further first cutting path S1′ toward the strip edge K. Similarly, the second laser cutting head is moved to the second puncture point E2 as soon as a collision with the first laser cutting head is no longer possible. Subsequently, the second laser cutting head is moved from the second puncture point E2 in the direction of the strip edge K along the further second cutting path S2′.

[0049] The travel paths of the laser cutting heads, i.e. the movement paths of the laser cutting heads when the laser is switched off, are marked with interrupted arrow lines in FIGS. 5 and 6 respectively. The cutting paths S1, S2 and the further cutting paths S1′ and S2′ are marked with solid lines.

[0050] FIG. 6 shows in comparison a top view of the sheet metal strip 1 according to FIG. 5. For the production of the sheet metal blank—as in FIG. 5—the first and second cutting paths S1, S2 and subsequently the further first cutting path S1′ and the further second cutting path S2′ are to be produced. In particular, using the apparatus according to the invention, it is now possible to guide some of the cutting paths S1, S2, S1′, S2′ from the strip edge K towards the strip interior I. In the present example, the first laser cutting head is first moved from the strip edge K in the direction of the first puncture point E1 along the first cutting path S1. At the same time, the second laser cutting head can be guided from the first puncture point E1 in the direction of the strip edge K along the second cutting path S2. The second laser cutting head is then moved along a travel path outside the sheet metal strip 1. Subsequently, the second laser cutting head is moved from the strip edge K into the strip interior I along the further second cutting path S2′. The first laser cutting head is moved along a travel path from the first puncture point E1 to the second puncture point E2. The first laser cutting head is then activated and moved from the second puncture point E2 along the further first cutting path S1′ toward the strip edge K.

[0051] As can be seen in FIG. 6, only a single laser cutting head is used at the first puncture point E1 and at the second E2 puncture point—in contrast to the example shown in FIG. 5. To avoid a collision of the laser cutting heads, it is no longer necessary to wait until one of the two laser cutting heads is at a sufficient distance from the puncture point E1, E2. The production of the first cutting path S1 and the second cutting path S2 can start simultaneously. The same applies to the production of the further first cutting path S1′ as well as the further second cutting path S2′. Apart from this, the traverse paths are shorter compared to the example shown in FIG. 5. Overall, there is a significant reduction in the process time for producing the sheet metal blank.

LIST OF REFERENCE SIGNS

[0052] 1 sheet metal strip [0053] 2 transport device [0054] 3 laser cutting device [0055] 4 gantry [0056] laser cutting head [0057] 6 control unit [0058] 7 cutting nozzle [0059] 8 first distance measuring device [0060] 9 second distance measuring device [0061] 10 third distance measuring device [0062] 11 comparison facility [0063] 12 control device [0064] 13 actuator [0065] 14 signal line [0066] 15a-f further distance measuring devices [0067] A axis [0068] E1 first puncture point [0069] E2 second puncture point [0070] I strip interior [0071] K strip edge [0072] L laser beam [0073] P.sub.1 first position [0074] P.sub.2 second position [0075] S1 first cutting path [0076] S1′ further first cutting path [0077] S2 second cutting path [0078] S2′ further second cutting path [0079] T transport direction [0080] U circumferential edge [0081] y y-direction [0082] z z-direction