Fraunhofer ILT and Dreher to present new laser blanking system at Euroblech

11 Sep 2024

Sheet metal processing method will be on show in Hanover between October 22-25.

The Fraunhofer Institute for Laser Technology (ILT) and Automatic-Systeme Dreher (Dreher) are together presenting an innovation in sheet metal processing at industrial trade show Euroblech 2024 from October 22 to 25 in Hanover, Germany: a demonstrator system for laser blanking that significantly increases process reliability and efficiency in production through the use of artificial intelligence.

As part of the joint project DIPOOL (Digital Process Online Optimizer for Intelligent Laser Machines), the ILT and 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,” said Dr. Frank Schneider, DIPOOL project manager and cutting group leader at ILT. “These technologies make it possible to detect process deviations in real time and make immediate adjustments to sustainably increase production reliability and speed. With the DIPOOL project, we really are setting new standards in sheet metal processing.”

The functional principle of the monitoring system is based on a “minimally invasive” laser modulation pattern. Minimal disturbances are imposed on the machining process, to which the process continuously responds with particularly characteristic, condition-dependent signals. AI can analyze these patterns particularly well, say the partners.

Industrial scale

Dreher, ILT and the pilot customer have cooperated on building an industrial-scale laser blanking demonstrator system and integrating system monitoring with AI and MILM. For this pilot customer, the Aachen-based institute has been developing the process over many years.

“By combining a new type of system design, the high-speed cutting process developed by Fraunhofer ILT and innovative process monitoring, we are now able to machine blanks dynamically with extremely short cycle times,” said Schneider.

The system to be demonstrated at Euroblech, which will be used to process cold-rolled strip products, is 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 lead to problems. MILM ensures that the cutting process remains continuously stable.

“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,” said Hasan Sarac, managing director of Dreher. “This means that we can optimize nesting and process large components. This is a decisive advantage that makes manufacturing in automotive production more cost-effective.”

Outlook and next steps

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. Because laser blanking does not require expensive tools, it reduces costs as it makes both storage and maintenance unnecessary.

After the presentation at Euroblech, the outputs of the DIPOOL project will proceed into the first industrial implementation. In cooperation with German engineering firm Bilstein Group as a pilot user, optimizations and extensions will then follow that are necessary for use in series production.