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Laser welding
Applications > Joining technology > Laser welding

Laser welding in continuous operation

 Machining heads for industry applications as well as suitable clamping technology and edge preparation are the keys to success. The welding head not only focuses the laser beam on the correct spot size, but it also measures, if necessary, the joint position right before the process and adjusts the laser spot into the correct position. Online monitoring of the welding process and if necessary, downstream seam check always guarantees a good result. Precitec provides everything from one source - finely adjusted to you application.

Applications
Welding head YW52 - with ScanTracker
Impeccable welding seams in thick-walled aluminium

When laser welding aluminium, the weld pool is quite distinctly fluid. Material expulsions and holes can occur, and these permit neither an acceptable weld quality nor good bonding. 


Visibly good results can be achieved using a coaxial seam tracking system and the precisely adjustable effective width of the laser spot. Consequently, it is not only thin components - generally the case with conduction welding - that can be welded. The use of the ScanTracker also permits conduction welding, with scan function, of thick-walled aluminium components. There is no need for expensive and complex post-treatment, above fall for visible seams. 

Welding head YW52 - with ScanTracker
Individual seam geometries

When housing and metal sheet structures from aluminium, steel, stainless steel and NF alloys are welded, the exterior welding seams are so-called visible seams. They should not have a raised form, and ought to fit into the component contour, in other words create flowing transitions.


Owing to the three-dimensional component geometry and the robot-controlled plant concept, seam tracking is unrelenting. Consequently, deviations in the component position are noticeable and can be compensated by a continuous position correction. The variably adjustable spot size makes the welding seam precisely as wide as the application requires.

Welding depth monitoring with airbag detonator cap

When welding airbag detonator caps, monitoring of the welding depth is of great importance: On the one hand, one is not allowed to weld through it, because the detonator cap is filled with an explosive detonating substance. On the other hand, it must me welded at a depth that is enough to ensure that the detonator cap is sealed. The welding depth on airbag detonator caps has been monitored by the Laser Welding Monitor LWM for several automotive suppliers since 1999. 

Welding head YW52 - basic model
Optimized performance welding of auto body connections

Welding of auto body components places great demands on processing quality. Precitec coaxial process monitoring is used by the innovation alliance Green Carbody Technologies, in order to ensure continuous process monitoring. Thereby, the laser power is also adjusted to the processing time, in order to attain the best possible quality. 

Welding head YW52 - basic model
Welding of backrests with the YW52

Laser beam welding is used often in the joining process for the metallic structure assembly of auto seats. Thereby, the individual pieces are connected to each other via a large number of step seams. Moreover, seat components are normally processed with multiple welding heads simultaneously, in order to maintain a lower cycle time. 

Follow complex curves

Part and stamping variation is often a fact of life. Rather than refurbishing or replacing every die and stamping machine in order to achieve exacting part repeatability, it is often easier to add a seam finding method to the assembly process. The ScanTracker, a welding head that integrates a real-time closed-loop seam-finding process, is an ideal choice for its speed, precision, and repeatability. Even on blind welds on the edge of a car door, the ScanTracker is able to follow complex curves and place the weld right where it is needed, every time.

Welding System FormWelder Plus
Precise welding of small contours

Gambrel sticks, so-called ISOFIX latch serve for attaching children's car seats. Welding small contours takes place on a stationary welding station with a programmable X/Y axis system integrated into the processing head. This separates the small contours with high path accuracy. Process monitoring also controls the safety-relevant parts to 100% on line. 1.5 million latches are produced in a double work station annually.

Laser welding with double coupling

When welding double couplings, a solid connection is the decisive criterium. Since, welding is done with small focal diameters, it must be ensured that the laser beam hits the joint exactly. This task is conducted by a high-precision seam position control. In order to ensure smooth production, laser power as well as the protective glass slot in the welding head is monitored online. 

Laser Path Finder LPF - system description
Roof seam welding with seam position control

The joining area is setup here in such a manner that the welding seam is located in narrow grooves on both sides of the roof, the so-called roof channels. The side roof flanges are connected to the side components via laser edge welding in these. The laser beam is positioned on the edge of the roof sheet metal in such a way that it melts evenly into the bottom plate. The seam guidance system LPF provides precise laser beam guidance of the entire length of the seam along the edge.

Tailored blanks laser welded

When welding tailored blanks, process reliability and thus fully-automated seam inspection is a must. The following forming process bonds the laser welding seam similar to that of the base material. Often, multiple systems are used for seam inspection. Process optimization takes place with the laser welding monitor LWM, seam inspection for geometry and local welding failures with the SOUVIS® system.  

To the Product
Seam Inspection System SOUVIS® 5000
Welding of rear axle drive with filler wire

Due to metallurgic conditions, today rear axle drives are often welded with laser and filler wire. Thereby, the seam quality and the seam position is decisive for the connection strength. The seam inspection system SOUVIS® measures both the position of the joint as well as the position and quality of the welding seam in one work cycle.

To the Product
Seam Inspection System SOUVIS® 5000
Brazing seam inspection of trunk lids and roofs

Brazing seams are susceptible to pores, which can be critical in the outer layer area of the auto body. The robot guided seam inspection system SOUVIS® easily detects the smallest pores to 0.2 mm, reliably and with very low false detection rates. The fully automatically control of brazing seams on roofs and trunk lids is state of the art today and applied worldwide.

To the Product
Welding of security-relevant components

Constant quality monitoring and documentation is required when welding security-relevant components. Thus, the in-process monitor LWM (Laser Welding Monitor) is used when welding seat slide adjuster and backrests. The LWM sensor unit can be adapted as both standard optic and scanner optic. 

Monitoring of the seam position when welding powertrains

The detection of the joining position is often a challenge for seam guides when laser welding gear wheels. Only the correct positioning of the laser spot ensures a smooth welding connection. The space-saving solution of the coaxial structure of the seam guide can be easily integrated into the welding machine. The sensor measures the position of the radial and axial joints precisely and it can be reproduced, even with small radii.
 

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