WO2024174021A1

WO2024174021A1 - System and method for de-coating components with a laser

Info

Publication number: WO2024174021A1
Application number: PCT/CA2024/050199
Authority: WO
Inventors: Michael BLÜMEL
Original assignee: Magna International Inc.
Priority date: 2023-02-20
Filing date: 2024-02-16
Publication date: 2024-08-29

Abstract

A method for processing a vehicle component. The method includes applying an upper coating to the vehicle component. The method also includes identifying at least one fastener region of the vehicle component at which a fastener is located. The method also includes de-coating the upper coating from the at least one fastener region with a laser.

Description

SYSTEM AND METHOD FOR DE-COATING COMPONENTS WITH A LASER

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This PCT International Patent Application claims the benefit of and priority to U.S. Provisional Patent Application Serial No. 63/446,974, filed February 20, 2023, titled “System And Method For De-Coating Components With A Laser,” the entire disclosure of which is hereby incorporated by reference in its entirety.

FIELD OF THE DISCLOSURE

[0002] The present disclosure relates to a system and method for de-coating components. More particularly, the present disclosure relates to a system and method for removing an upper coating, such as a stone chip protection layer, from a fastener region of a vehicle component with a laser to make the fastener region tailored to receive fasteners.

BACKGROUND

[0003] This section provides background information related to the present disclosure which is not necessarily prior art.

[0004] It is known for components of automobiles, such as chassis components, to have a base layer, like an E-coating, which is covered with an upper coating, like a stone chip protection layer, to provide an added layer of protection. It is generally desirable to not locate the stone chip protection layer at regions of fasteners, e.g., screws or bolts, in order to provide proper fastening conditions. To address this, it is common to cover the fastener regions with a masking tape prior to applying the stone chip layer such that the stone chip protection layer is not present at the fastener regions after removal of the masking tape. However, applying and removing the masking tape requires significant manpower, time and materials, and produces waste. Accordingly, there remains a need for improvements to coating deposition processes for components.

SUMMARY OF THE INVENTION

[0005] According to an aspect of the disclosure, a method for processing a component is provided. The method includes applying an upper coating to the component. The method also includes identifying at least one fastener region of the component at which a fastener is located. The method also includes de-coating the upper coating from the at least one fastener region with a laser.

[0006] According to another aspect of the disclosure, a system for processing a component includes a supporting device for holding the component. The system also includes a laser that is configured to emit a beam to remove an upper coating of the component. The system also includes a vision element that is configured to identify fastener regions of the component. The system also includes a controller that is electrically connected to the laser and the vision element, and is configured to instruct the vision element to determine at least one fastener region of the component and to instruct the laser to de-coat the upper coating at the fastener region without disrupting the upper coating outside of the fastener region.

[0007] According to another aspect of the disclosure, a method for processing a vehicle component includes applying a base coating to the chassis. The method also includes applying an upper coating over the base coating. The method also includes identifying at least one fastener region of the vehicle component at which a fastener is located. The method also includes decoating the upper coating from the at least one fastener region with a laser such that the fastener region is adapted to receive the fastener without removing the upper coating outside of the fastener region. [0008] The process of de-coating the upper coating with a laser can be automated and there is no need for consumables like masking tape, thus providing an efficient and inexpensive process. Furthermore, the laser can be tuned such that it bums off the upper coating while preserving a base coating such that attributes of the underlying base coating like corrosion protection are maintained. This process may be executed without disrupting the upper coating which surrounds the fastener region.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0010] FIG. 1 is a schematic diagram of an embodiment of a system for laser de-coating components according to an aspect of the disclosure;

[0011] FIG. 2 is a perspective view of a vehicle component having an upper, stone chip protection coating, being removed from a base, e-coat, coating with a laser with the system for laser de-coating;

[0012] FIG. 3 is a perspective view of a vehicle chassis component, illustrating a fastener region of the component at which an upper coating is removed with a laser;

[0013] FIG. 4 is a perspective view of a system for laser de-coating a component according to an aspect of the disclosure, illustrating a laser pointed at a fastener region of the vehicle chassis component of FIG. 3; and

[0014] FIG. 5 is flow diagram of a method for removing an upper coating from a component with a laser. DESCRIPTION OF THE ENABLING EMBODIMENT

[0015] Referring to the figures, wherein like numerals indicate corresponding parts throughout the several views, a system 10 is generally shown for processing a component, such as a vehicle component like a chassis, frame, trailer hitch or door panel.

[0016] More particularly, with reference to FIG. 1, the subject system 10 is configured to remove an upper coating 12 from a component 14 in a fastener region 16 at which a fastener 17 is located during an assembly process of the component 14 in order to provide proper fastening conditions. The fastener region 16 may include the fastener 17 itself as well as the material immediately proximate the fastener 16, or the spot at which a fastener 17 will be located at a later stage in the assembly process. The upper coating 12 may be positioned over a base coating 20, and the system may be configured to remove only the upper coating 12 without disrupting the underlying base coating 20.

[0017] The base coating 20 may include a corrosion resistant layer like an electro coating (E-coating). The upper coating 12 may include a protective coating like a stone chip protection coating or powder coating. The subject system may be used to remove upper coatings 12 such as a stone chip protection layer 12 or powder coating from a chassis component of a vehicle.

[0018] The subject system 10 includes a laser 18 which is capable of pinpointing an exact location of the fastener region 16. The laser’s 18 pattern, intensity / power and other parameters are fine-tuned to only de-coat the upper coating 12 without disrupting underlying base coatings 20 or the upper coating surrounding the fastener region 16. The laser 18 is also tuned to not disrupt a flatness of the base coating 20 (i.e., avoid creating dents), nor to interfere with a thickness of the base coating 20. [0019] The system 10 includes a supporting device 22, such as a jig or rotating table, for holding the component 14. The supporting device 22 may be moveable/translatable and rotatable in any, and all directions, e.g., as schematically illustrated by arrows in FIG. 1. The supporting device 22 may include an actuator 24 for providing the movement of the supporting device 22. A controller 26 is electrically connected to the supporting device 22 for providing instructions to the actuator 24 to provide instructions to execute specific movements. Movements of the supporting device 24 may be pre-programmed, automated or manually controlled by an operator. [0020] As illustrated in FIG. 2, the laser 18 projects a beam 28 on the component 14 to remove the upper coating 12 and thus reveal the base coating 20. As shown, the laser 18 may have a generally square-shaped pattern of the beam 28 from a squared-optical fiber, which is capable of providing a large surface area. Other shapes may be used without departing from the scope of the subject disclosure. Furthermore, the laser 18 may be tuned to a desired power / intensity based on specific applications. According to the preferred embodiment, the laser 18 is configured to be oriented substantially perpendicularly to the surface of the component 14 such that an equal energy deviation is provided. According to an aspect of the disclosure, a focal length of the laser 18, i.e., a distance between a lens of the laser 18 and the component 14, is within 2mm with a focus area is approximately 2 mm.

[0021] With reference back to FIG. 1, the system 10 also includes an adjustment mechanism 30 for orienting the laser 18 into different positions. Various types of adjustment mechanisms 30 may be used, such as a robot arm 30 which is configured to move and rotate in any direction. The adjustment mechanism 30 is electrically connected to the controller 26 for providing instructions to the adjustment mechanism 30 to provide specific movements. Like the supporting device 24, movements of the adjustment mechanism 30 may be pre-programmed, automated or manually controlled by an operator.

[0022] The system 10 further includes a vision element 32 that is coupled to the adjustment mechanism 30 and/or laser 18 and electrically connected to the controller 26 for scanning the component 14, determining fastener regions 16 on the component 14 and orienting the laser 18 to the fastener regions 16 such that the laser 18 may remove the upper coating 12 from the fastener regions 16 while avoiding the upper coating 12 from the surrounding area.

[0023] FIGS. 3-4 illustrate example chassis components 14 for a vehicle and an associated laser 18 which is used to remove an upper coating 12 comprised of a stone chip protection coating which overlies a base coating 20 comprised of an e-coating. The component 14 is supported by a supporting device 22, and the laser 18 is supported by an adjustment mechanism 30 which is configured as a 3-axis robotic arm 30. More particularly, FIGS. 3-4 illustrate fastener regions 16 of the component at which the stone chip protection coating 12 is removed. The laser 18 of FIG. 4 can be moved via the robotic arm 30 to different fastener regions 16 of the component 14.

[0024] According to an aspect of the disclosure, the upper coating 12 has a different color than the base coating 20 to aid an operator or visual element 32/controller 26 to visually determine when the upper coating 12 has been removed without also eliminating the base coating 20. In other words, the color difference between the upper and base coatings 12, 20 can be used to establish that the upper coating 12 has been satisfactorily removed without damaging the base coating 20.

[0025] With reference to FIG. 5, methods for processing a vehicle component 12 with the subject system 10 are provided. A method includes 100 applying a base coating 20 to the component 12. In the example embodiment, the component 12 is a vehicle chassis component 12 and the base coating 20 is an e-coating to provide corrosion resistance capabilities. According to the method, the entire, or substantially the entire surface of the component 12 is coated with the base coating 20.

[0026] The method continues with 102 applying one or more upper coatings 12 over the base coating 20. The upper coatings 12 may include such coatings as a stone chip protection layer and a powder top coat layer. It is known to apply a stone chip protection layer to chassis components to prevent damage to the chassis during use of the vehicle.

[0027] The method continues with 104 identifying at least one fastener region 16 of the vehicle component 12 at which a fastener 17 is or will be located. Locations of the fastener regions 16 may be pre-programmed into the controller 26, the vision element 32 may seek out and locate the fastener regions 16, or the fastener regions 16 and/or may be manually located by an operator.

[0028] The method continues with 106 aligning the laser 18 with one of the fastener regions 16 based on the identified locations of the fastener regions 16. Aligning the laser 18 with the fastener regions 16 may include moving the supporting device 22, adjustment mechanism 30, or both. Aligning the laser 18 may happen automatically via instructions from the controller 26, or manually by the operator.

[0029] The method continues with 108 de-coating the upper coating 12 from the fastener region 104 that the laser 18 is in alignment with. As will be discussed in further detail below, the laser 18 is tuned / programmed such that it removes only the one or more upper coatings 12 without removing the one or more base coatings 20. The laser 18 is also configured to only remove the upper coating 12 from the fastener region 16, and not from the region which surrounds the fastener region 16. As part of this process, the controller 26 and/or vision element 32 may be configured to define a digital boundary around the fastener region 16 such that the upper coating 12 is only removed from the fastener region 16.

[0030] According to another aspect of the disclosure, the base coating 20 is of a material that is configured to absorb the laser energy to a greater extent than the upper coating 12 such that the upper coating 12 may be removed without impacting the base coating 20. According to a preferred embodiment, the upper coating 12 requires 50% less energy to be de-coated than the base coating 20. Likewise, thicknesses of the upper coating 12 and base coating 20 may be selected in conjunction with tuning an intensity of the laser 18 to provide an optimized arrangement which efficiently removes the upper coating 12 without damaging the base coating 20.

[0031] The method may continue with 110 repeating the above steps any number of times and for any number of fastener regions 16.

[0032] The method may further 112 including connecting the treated component 12 with another component with a fastener 17 at the fastener regions 16.

[0033] In view of the above, the step of de-coating the upper coating 12 with a laser 18 can be automated and there is no need for consumables like masking tape, thus providing an efficient and inexpensive process. Furthermore, the laser 18 and/or upper and base coatings 12, 20 can be tuned such that the laser 18 burns off the upper coating 12 while preserving the base coating 20 such that attributes of the underlying base coating 20 like corrosion protection are maintained. The process may be fully automated via the controller 26 and various actuating mechanisms, or may be manually executed. [0034] Obviously, many modifications and variations of the present invention are possible in light of the above teachings and may be practiced otherwise than as specifically described while within the scope of the appended claims. These antecedent recitations should be interpreted to cover any combination in which the inventive novelty exercises its utility. The features of different embodiments described herein are combinable with one another even if not expressly discussed.

Claims

CLAIMS What is claimed is:

1. A method for processing a component; applying an upper coating to the component; identifying at least one fastener region of the component at which a fastener is located; and de-coating the upper coating from the at least one fastener region with a laser.

2. The method as set forth in claim 1, wherein the upper coating proximate the fastener region is not de-coated.

3. The method as set forth in claim 1, wherein the upper coating is comprised of at least one of a stone chip protection coating and / or a powder coating.

4. The method as set forth in claim 1, wherein the component is a chassis component for a vehicle.

5. The method as set forth in claim 1, further including applying a base coating to the component prior to applying the upper coating, and wherein applying the upper coating includes applying the upper coating over the base coating.

6. The method as set forth in claim 5, wherein the base coating is not damaged during de-coating of the upper coating.

7. The method as set forth in claim 1, wherein the laser is connected to a robotic arm that is configured to move in three dimensions, and wherein the laser is moved into alignment with the fastener region of the component prior to de-coating the upper coating from the at least one fastener region.

8. The method as set forth in claim 1, wherein the at least one fastener region includes a plurality of fastener regions.

9. A system for processing a component, comprising; a supporting device for holding the component; a laser configured to emit a beam to remove an upper coating of the component; a vision element configured to identify fastener regions of the component where a fastener is or will be located; and a controller electrically connected to the laser and the vision element and configured to instruct the vision element to determine at least one fastener region of the component and to instruct the laser to de-coat the upper coating at the fastener region without disrupting the upper coating outside of the fastener region.

10. The system as set forth in claim 9, wherein the controller is configured to instruct the laser to de-coat the upper coating while preserving a base coating under the upper coating.

11. The system as set forth in claim 9, further including an adjustment mechanism coupled to the laser and configured to move the laser in response to instructions from the controller to align the laser with the fastener region of the component.

12. The system as set forth in claim 11, wherein the adjustment mechanism is a robotic arm.

13. The system as set forth in claim 9, wherein the support device is moveable in response to instructions from the controller for aligning the component with the laser.

14. A method for processing a vehicle component; applying a base coating to the vehicle component; applying an upper coating over the base coating; identifying at least one fastener region of the vehicle component at which a fastener is located; and de-coating the upper coating from the at least one fastener region with a laser such that the fastener region is adapted to receive the fastener without removing the upper coating outside of the fastener region.

15. The method as set forth in claim 14, wherein the base coating is an e-coat layer, and wherein the upper coating is comprised of at least one of a stone chip protection coating and / or a powder coating.