Sharing Excellence in Laser Processing Systems. Robot based 3D metal cutting

Transcription

1 Sharing Excellence in Laser Processing Systems Robot based 3D metal cutting 1

2 Overview - Content About JENOPTIK Basic technology BIM Performance and applications Low footprint machine concepts Summary and outlook 2

3 JENOPTIK AG History Carl Zeiss Jena GmbH gives rise to the creation of Jenoptik GmbH. 17,000 employees are dismissed Demolition, renovation and development of former Zeiss production sites 1846/ /1998 Carl Zeiss University mechanic and entrepreneur; founded the workshop for precision mechanics and optics in Jena in 1846 Ernst Abbe Innovator and reformer; in 1867 scientific director of and in 1875 partner in the Zeiss workshop 1945/46: Transfer of patents and dismantling of parts of the company by the U.S. and Soviet armies. 1946: A new Zeiss Company is founded in Oberkochen. The Zeiss plant in Jena, East Germany, is converted into state property. In 1996 Jenoptik GmbH was converted into a joint stock corporation. Going public: June 16,

4 JENOPTIK AG Divisions and Business Units Corporate Center Corporate Center Lasers & Material Processing Optical Systems Industrial Metrology Traffic Solutions Defense & Civil Systems Lasers Laser Processing Systems Optics Micro Optics Optoelectronic Systems Roughness and contour measurement Form measurement Equipment Service Providing Mechatronics Sensor Systems Dimensional measurement 4

5 Processing Capabilities Tubes Structural parts Housings Cutting 3D (hydro) formed metal parts and tubes like exhaust piping, car components (cross car beam ) Cutting structural parts especially for car body components (A, B, C Pillars, bulkheads ) Cutting Functional holes and contours for metallic appliances, housings, canisters Beam - In - Motion 5

6 Overview - Content About JENOPTIK Basic technology BIM Performance and applications Low footprint machine concepts Summary and outlook 6

7 System Design and Features - Beam Architecture BIM - Beam In Motion Technology standard fibre Benefits High reliability proven in the automotive industry Higher accessibility processing complex parts Most accurate robot system with highest dynamics Lower service and maintenance No wear out of process fibre due to reliable internal mirror system Axis 6 removed Axis 5 redesigned for laser light transport 7

8 System Design and Features - Contamination Protection Pressuring the system Purge robot casting with dry air Purge beam delivery system with dry air Airtight design of robot Airtight sealed flanges Cutting head Head is completely sealed No contamination from fiber Purge pressure on top and below the cutting optic 8

9 Comparison with Traditional Robot Systems small bulky No moving fiber No limitation of movement due to fiber transport 2x more compact then traditional robot / working fiber design High degree of rotation without working fiber fatigue issue 9

10 System Design and Features Cutting Head Optimized cutting head design Specifically adapted cutting head without fiber coupler with < 5 kg weight -> precision / speed Slim design -> less collisions Crash guard head Integrated distance control with fast z-axis Up to 300 mm/s processing speeds 10

11 Overview - Content About JENOPTIK Basic technology BIM Performance and applications Low footprint machine concepts Summary and outlook 11

12 Requirements to Meet UHSS Processing Specifications Accuracies OEM specs have to be reached in any case outer trim +- 2mm standard holes µm locator holes +- 50µm Speed benchmark around the world is the speed / cycle time which is reached by a gantry system overall cycle time most valuable Quality roundness of holes burr free straight cuts 12

13 Limitations Known from Robot Based Cutting Systems Accuracies path accuracies of robot systems are not sufficient waviness of straight cuts accuracies depend on the number of joints of the robot to be moved simultaneously Speed speed and dynamics depend on the weight the robot has to move time to get a new product running Quality roundness of holes depends on speed Improvements lightweight robot BIM special cutting procedures for contours special offline programming 13

14 Analysis of the Robot Capability in the Total Work Envelope standard contour plate placed and processed on different positions in the working area CMM measurements on 100 parts in total targeting OEM specs for cut quality on UHSS parts C1 Rect. C3 C2 S. Slot C4 C5 C6 Hex.C5 L. Slot 14

15 Analysis of Different Accuracy Features 15

16 Analysis of Different Accuracy Features conclusion: almost all accuracy features for cutting press hardened steel parts are proven within the tightest OEM spec basis for any kind of discussion in the automotive industry for integration of a robot cell 16

17 Accuracy Comparison Robot (JENOPTIK) vs. Gantry 17

18 Accuracy Comparison Robot (JENOPTIK) vs. Gantry 18

19 Accuracy Comparison Robot (JENOPTIK) vs. Gantry 19

20 Applications Cutting of Press Hardened Steel Parts 3D cutting of press hardened steel parts material Usibor; et al. material thickness 1 to 2.5 mm as well as double planches up to 4mm Performance speeds >200 mm/s for straight cuts speeds up to 60 mm for contours accuracies for locating holes down to ± 50 µm meets common OEM specs A 1 A 2 A 3 A A 5 4 A 6 20 A 9 A 7 A 1 0A 8 A 1 1 A A A 1 4

21 Offline Programming CENIT Download Offline-Programming Translate Robot Code Fixture Design Work piece mounted in the work cell Technologyorientated programming Data Clean-Up Data Integration Intelligent Contour Search 22

22 Comparison Third Party Validation Third party validation on a in production Hot Stamp part 30 laser cut gantry parts (currently running production) 30 laser cut parts by Jenoptik BIM Jenoptik BIM results: Cycle time Same as gantry CMM results All measurement points meet OEM spec Hole location Hole Diameter variation Hole circularity variation Edge trim Variation Production Reliability test of >40000 parts passed Ease of Programming Same as Gantry (based on Cenit) 23

23 Further Possible Applications Cutting of 3D Formed Tubes Cutting of 3D formed tubes material: steel, stainless steel, aluminium material thickness 0.5 to 5 mm Performance typical cutting speed is between 40 to 70 mm/sec of a 2.5 mm thick stainless steel tube with outside diameter of 80 mm accuracies for locating holes down to ± 50 µm Customers OEMs, Tier 1 making car body elements and exhaust systems 24

24 Overview - Content About JENOPTIK Basic technology BIM Performance and applications Low footprint machine concepts Summary and outlook 25

25 System Configurations Double BIM Double BIM for processing (several) parts using two robots and two beam paths to reduce cycle time 26

26 System Configurations Multi Robots for Line Integration Integration of multiple robot installation in various production lines Cost efficient systems with small floor space requirements High throughput Flexible configuration allows cutting of a wide range of different parts Processing range of one single robot: app. 1,400x800x500 mm³ Highest flexibility to define the right BIM configuration for any specific application 27

27 Overview - Content About JENOPTIK Basic technology BIM Performance and applications Low footprint machine concepts Summary and outlook 28

28 summary and outlook Summary gantry systems are a proven machine setup to cut presshardened steel parts limitations in flexibility of footprint and adapted system configurations can only be done by robot systems robot systems and especially JENOPTIK BIM might be able to give new perspectives for cutting UHSS parts efficiently A multi robot cutting approach will be proven in industry within 2014 with lowests laser off time 29

29 Business Unit Laser Processing Systems Application Support Center Join us for a test drive to verify your investment! 15 different laser machines available Test your own applications with our application team Prototype production, pre-series testing Development of material related processes Support of process related product design Training 30

30 Lasers Processing Systems