PRODUCT REVIEWS
AI for more efficient laser manufacturing
High-tech company TRUMPF has developed an artificial intelligence ( AI ) application for lasers that is designed to make manufacturing more efficient .
“ Electric car manufacturers , for example , can use it to produce more electric motors in less time . It also results in less rework and scrap ,” TRUMPF told ISMR .
“ In the future , we want to use AI to raise the overall system of lasers , optics , sensor technology and software to a new level of performance . We are therefore pushing ahead with the development of further AI solutions that will make laser processes in industry even more powerful and profitable ,” said Christian Schmitz , CEO Laser Technology , TRUMPF . The AI process has already proved itself practically in series production for e-mobility and can be used in a variety of laser welding applications .
At the LASER - World of Photonics trade show , TRUMPF demonstrated to the public how AI supports laser welding . It presented its AI solutions EasyModel AI , which creates an algorithm and the AI Filter for VisionLine Detect , which applies that algorithm .
TRUMPF customers can apply the algorithm with the AI filter .
“ To ensure that the weld seam is always in the right place , the laser ’ s sensor technology must position the weld geometry precisely on the component , otherwise there is a risk of rejects . Dirt or scratches on the component , poor lighting conditions in the work area or highly reflective materials such as copper make positioning difficult . Our AI solution supports image processing and thus reduces such interference ,” commented TRUMPF .
The user must train the artificial intelligence before it is used . To do this , the machine setter marks the relevant component areas in the corresponding image medium . Programming knowledge , says TRUMPF , is not required for this .
“ Using this system is as simple and intuitive as using the painting and drawing programs that everyone knows from smartphones or computers . The AI model created by the training is then used in the AI filter for the VisionLine Detect image processing system .
TRUMPF offers manufacturing solutions in machine tools and laser technology . The company drives digital connectivity in manufacturing through consultancy , platform products and software . In 2021 / 22 , the company employed some 16,500 people and generated sales of about 4.2- billion euros . With over 80 subsidiaries , the TRUMPF Group is represented in nearly every European country as well as in North America , South America and Asia . The company has production facilities in Germany ; France ; the United Kingdom ; Italy ; Austria ; Switzerland ; Poland ; the Czech Republic ; the United States ; Mexico and China . n www . trumpf . com
Deep-drawing smart lubrication system
After the supply of a first lubrication device in 2019 and a second in 2021 , UK stainlesssteel sink producer AGA Rangemaster recently installed its third Dietronic SAGOMA-series lubrication system for its deep drawing process . The investment has increased yield and led to a significant reduction in oil consumption , according to AGA Rangemaster .
“ These considerable benefits made the justification for a second , and then a third , system very straightforward decisions . At the time , we were using a couple of lubricators supplied by another company , but we were not very satisfied with them . The technology was outdated and so we started to seriously consider a restoring project for the lubrication stations ,” explained Jason Allaway , Group Manufacturing Director , AGA Rangemaster .
At Dietronic ’ s premises , it inspected a SAGOMA system with conveyors in operation and did some tests to evaluate the machine ’ s functionality . It also had more specific requirements for its particular application .
“ The package was complete including inlet / outlet conveyors with lateral centring unit , a feature that is very useful for the sink manufacturing process and something that we considered for our project . We saw how the spray patterns could easily be programmed for the variety of different blanks used to produce
First DieTronic Sagoma machine with conveyors provided to Aga Rangemaster .
the sinks . A very smart feature of SAGOMA is the ‘ teach-itself ’ function of the blank shape with a quick pass through the sensor bank . After this , the operator can programme exactly where the oil is needed and the quantity to apply by application in 50mm x 50mm sections , easily selectable from the touch-screen panel . The recipe system then stores each programme for rapid start-up after changeovers . This was exactly what we needed ,” continued Jason Allaway .
After two years , the company decided to implement a second SAGOMA system featuring an external automatic spray-head cleaning system . The device is designed to automatically clean quickly and facilitate off-line maintenance operations on the spray heads and internal manifolds . The procedure implements a full flushing , cleaning , drying and diagnostic check of each nozzle with each stage displayed on the HMI in ‘ real-time ’ information . The process is completed quickly with a 20-nozzle system in just over five minutes .
“ Both spray heads can be removed , cleaned and returned to the machine in around 15 minutes . If you have a set of spare additional spray heads set ( as in our case ), you won ’ t have to stop your production ,” outlined Allaway .
“ The greatest difference that we immediately noted with the first system was the significant saving in oil consumption , compared to our previous lubricators . Our oil consumption has reduced by more than 70 % with the Dietronic system compared to the old lubricators . We also marked a noticeable improvement in the working environment , such as greatly decreased oil mist ( thanks to the high-level extraction system with HEPA filter ) and reduced oil on the floor and on the machinery ,” he added .
DieTronic specialises in sheet-metal lubrication and the protection of tubes and profiles , as well as customised process automation solutions . n
www . agarangemaster . com
www . dietronic . eu
52 | ismr . net | ISMR July / August 2023