One-sided, non-contact laser welding combined with high-speed scanning lenses reduces weld time while increasing productivity.
Remote laser welding has become a means of replacing resistance spot welding in traditional automotive body-in-white applications. According to industry surveys, there are more than 60 installed equipment, mainly in Europe and North America. Remote laser welding technology combines the technical and economic advantages of single-sided, non-contact laser welding, and combines it with the advantages of high-speed scanning lenses, greatly reducing welding time and adding a total of the entire welding process Productivity.
The advantages of remote laser welding are most significant, if compared to some laser/robot welding cycles: 20mm seam welding can be completed in 0.2-0.4 seconds, repeat positioning time is up to 3 seconds, and for remote welding The welding time is the same and the repeat positioning time is only 0.2 seconds. A key advantage of remote soldering is the reduced positioning time due to the high speed beam scanning device (see Figure 1).
Figure 1 The key advantage of remote soldering is the reduction of positioning time by high-speed beam scanning
Comau Pico has long worked to advance the development of remote laser welding technology, and they have opened up new areas in body-in-white production by working with forward-thinking car manufacturers. One of the company's early achievements was in collaboration with Rofin Sinar, a CO 2 laser-based remote welding device that uses scanning lenses to reflect beams at high speeds and weld multiple weld locations on body parts.
On a typical part of the Fiat Marea, remote CO 2 laser welding is used to replace resistance spot welding, which is mainly used to eliminate the cost of using adhesive on the rear door of the car. In this application, the total laser seam welding time is 5 seconds. In the welding of the door frame of the model, 43 laser welds can be completed in only 30 seconds, replacing the traditional resistance spot welding. In both applications, the reduction in repositioning time was as high as 94%.
After working with Rofin to gain experience in these applications, Comau began to realize that the system offers the following advantages: high productivity (up to 120 solder joints per minute), high flexibility, reduced footprint (most automotive plants) One of the main cost factors) and the ability to weld a variety of different form factors.
However, if the remote welding systems used are not considered, they must be tightly clamped to each welding station from the point of view of the parts. This necessitates the design and fabrication of fixtures and is even very complex in some applications. On the other hand, it has the advantage of being more economical and consuming less space, and only one welding fixture is required for spot welding using 6 to 8 jigs.
Comau also recognizes that there are some limitations to the scan box on a conventional remote soldering system because it is not possible to move the remote solder joint. So Comau developed and applied for a patent, a fast beam delivery system that provides four-axis motion when mounted on a conventional gantry-type system (see Figure 2). The new unit in this way delivers higher throughput, the ability to move the beam over the part at high speeds instead of moving parts, and reduces the complexity and cost of the associated tools. This concept allows the user to complete the weld anywhere within the gantry frame.
Figure 2 The traditional scan box is replaced by a patented fast beam delivery system.
In cooperation with Agilaser, more than 12 or more remote laser welding equipments are now operating at Fiat's various plants in Italy. In Mirafiori they are welded parts for both Idea and Musa models; in Melfi they have been welding Punto parts, in Cassino they Solder the new Stilo parts. The system was also installed at Renault's plant in Novo Mesto, Slovenia, for welding parts of Clio and Twingo, as well as parts of the Megane plant in Saundoville, France, and parts of Stola, Ducato and Alfa159 in Pomigilano, Italy.
At the Mirafiori plant, a set of Agilaser laser equipment replaced a robotic resistance spot weld line. It uses a double-clamp remote welding system for the door assembly line, reducing production investment by 15% and increasing productivity by 20% while reducing floor space. - A 50% reduction compared to the traditional four robotic welding system. The result is a 30% reduction in unit cost after laser remote welding.
Renault used a set of Agilaser welded C85 front door components (see Figure 3) to replace the original system requiring 12 robotic resistance welding. The original system required a footprint of 1050 m2, while the Agilaser with 5 robotic processing stations only occupied 808 m2. . Two Agilasers produced parts in a 66-second cycle, welding 93 right and left laser welds, while previously required resistance spot welding of 130 right and left welds. At Renault, an Agilaser welds 38 laser welds on the front door of the C65 model, using only two identical fixtures.
Figure 3 Renault uses an Agilaser to weld the front door components of the C85
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1.with 3000 square meter factory about 35 workshop workers and 25 office workers.
2.More than 20 sets of advanced machines with more than ten years domestic trade experience and international trade experience.
3.Manufacture and supply good quality automatic doors
4.With ISO 9001 Certification and many others certifications
5. Excellent DC brushless motor , high wear-resistant qualities wheels and reasonable structure design makes it more stable, quiet, longer life
6.Our Service system is perfect
Controller Dimensions : 85×124×600mm
Weight :12 kg
Maximun leaf weight :150 kg
Open range : 70°~115°
Closing speed : 10~43 cm/s
Door hold time :0.5~10 seconds
Main Power :AC 220V~250V,50~60 Hz
Maximum current :1A
Maximun motor power:55W
Wait Power :14W
Fuse :Minimum 3.5 ASlow
Operating Temperature : -30℃ ~+50℃
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