The Fraunhofer Institute for Laser Technology ILT and Automatic-Systeme Dreher GmbH presented a groundbreaking innovation in the field of sheet metal processing at Euroblech: a demonstrator system for laser blanking that significantly increases process reliability and efficiency in production through the use of artificial intelligence.
In modern production, especially in the automotive industry, the precise and efficient cutting of blanks from coils is a central task; the requirements are constantly increasing. Traditional methods, such as punching, are reaching their limits, especially when it comes to flexibility and resource conservation in production. Added to this is the need to reliably and safely monitor continuous production processes in order to avoid expensive system downtimes and production losses. Disruptions caused by cutting interruptions, for example, can be detected and avoided at an early stage with additional sensors and control mechanisms. As part of the joint project DIPOOL (Digital Process Online Optimizer for Intelligent Laser Machines), the Fraunhofer Institute for Laser Technology ILT and its project partners are developing solutions to improve the efficiency and safety of laser cutting and welding processes. DIPOOL is funded by the German Federal Ministry of Education and Research (BMBF) and combines the expertise of leading industry and research partners to develop pioneering solutions for Industry 4.0. “The project aims to use artificial intelligence and minimally invasive laser modulation to optimize process monitoring and control in sheet metal processing, with a particular focus on thin sheet metal and laser blanking,” explains Dr. Frank Schneider, project manager of DIPOOL and group manager for cutting at Fraunhofer ILT. “These technologies make it possible to detect process deviations in real time and make immediate adjustments in order to sustainably increase production reliability and speed. With the DIPOOL project, we are really setting new standards in sheet metal processing.” The functional principle of the monitoring system is based on a ‘minimally invasive’ laser modulation pattern (MILM). Minimal disturbances are imposed on the machining process, to which the process continuously responds with particularly characteristic, condition-dependent signals. Artificial intelligence (AI) can analyze these patterns particularly well.
© Fraunhofer ILT, Aachen
Cooperation between Fraunhofer ILT and Dreher Automation
An industrial-scale laser blanking demonstrator system and the integrated implementation of system monitoring with AI and MILM is the result of close collaboration between Automatic-Systeme Dreher GmbH, Fraunhofer ILT and the pilot customer, for whom the Aachen-based institute has been developing the process over many years. Dreher Automation is an experienced specialist for automation systems in the field of forming manufacturing processes and contributes its expertise in the development of high-precision machine solutions. “The combination of a new type of system concept, the high-speed cutting process developed by Fraunhofer ILT and innovative process monitoring enables extremely dynamic machining with the shortest cycle times,” explains Dr. Schneider. Fraunhofer ILT and Dreher Automation will be presenting the demonstrator system on stand 27-H82 at Euroblech 2024. The system, which is to be used in the processing of cold strip products, among other things, is specially designed to maximize process reliability when processing coils. The AI-based systems analyze the process signals in real time and detect even the smallest deviations before they can lead to problems. MILM ensures that the cutting process remains continuously stable, which minimizes scrap rates and significantly increases the overall productivity of the system. “The new concept of overlapping work areas of two processing heads with continuous belt transport in the system enables maximum flexibility and resource-efficient production,” explains Hasan Sarac, Managing Director of Automatic Systeme Dreher GmbH. “This means that each laser can process exactly what is required. This enables optimized nesting and the processing of large components. This is a decisive advantage for economical manufacturing in automotive production.”
Fraunhofer ILT, Aachen
Promising test runs
The demonstrator system implements the findings and results of the DIPOOL project. The design of the system is primarily aimed at automotive production, in particular the cutting of structural components and other sheet metal parts from coils. This saves immense costs: Because laser blanking does not require any tools, there are no costs for expensive tools or for storage and maintenance. And downtimes due to tool changes are also eliminated. Test runs show the advantages of the new system concept and continuous production from the coil, which leads to optimized nesting and the associated material savings, one of the key levers for the system’s resource efficiency. Higher productivity, reduced scrap rates and flexible adjustment of the cutting contour in tryout production – decisive advantages. “Our collaboration with the Fraunhofer ILT as part of the DIPOOL project impressively demonstrates how mechanical engineering and innovative technology can go hand in hand to create a new benchmark for the industry,” summarizes Hasan Sarac. After the presentation at the Euroblech trade fair, the results of the DIPOOL project will flow into the first industrial implementation. In cooperation with the pilot customer, optimizations and extensions will then follow that are necessary for use in series production. Web: www.dreher.de Euroblech Hall 27, Stand H82
