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Starting situation
When incorporating new forming tools, it is important on the one hand to modify the tool so that dimensionally accurate sheets can be produced, and on the other hand to ensure that the produced sheets can be assembled in the body shell. The modification we carried out to a bending operation of a tool serves to improve the mountability of the sheets when using robotic systems. Two areas on the flange of an approx. 1 m long sheet must be corrected over a length of 400 mm. The modification is specified by support points along the flange determined from the measurement report of the sheet metal. Between the support points, the surface must continue without buckling.
Procedure
We carried out reverse engineering with the software Tebis, after digitizing the relevant area. This data forms the basis for the modification design. We apply the additional required material using our mobile welding robot. The robot can quickly and efficiently weld even larger areas without defects. Then, we used our measuring technology to check whether the material application in the modification area was sufficient.
This data also forms the basis for CAM planning for milling. Using our mobile CNC milling system, we mill the applied material on the basis of the previously carried out modification design. Models of our welding and milling system are stored in the Tebis planning software. This enables us to use planning data for collision control and thus work reliably even in areas that are difficult to access. Finally, we hand over the tool to our mechanics, who finalize the modification in the tryout and carry out the finishing touches.
Advantages
Thanks to the interaction of our welding and milling systems and measuring technology, shape changes with material application can be realized efficiently and cost-effectively on site. Our Lisa welding robot is a fast and precise alternative to manual build-up welding. Especially for large areas, we are more cost-effective this way. We reduce the subsequent tryout effort to a minimum through precise processing and quality control with our measuring technology. The service also includes data recording of the "old" current state before modification, reverse engineering, modification design, additive robot welding, CNC-controlled mobile milling, tryout and final manual incorporation. We also record the new current state of the tool after the modification with our measuring systems for data maintenance.