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Fiber laser welding body in white in the production application
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With the increasing size of the automobile industry, the application of resistance spot welding and laser remote welding has been considerable size. There are some people in favor of, also some people oppose this application. The main advantage of laser remote welding is a high efficient welding efficiency, and has all the advantages of the laser welding, welding cycle time is obviously shortened. Advantages of resistance spot welding is clamped with a deep the technology itself, IPG photon Limited has the torch in the new laser line LSS in a combination of these advantages.
Line laser welder can before welding resistance spot welding parts like like grip, and then to the oscillation mode, start a number of 10mm length of laser seam welding. Laser welding and laser beam path in the hollow structure of fixture, so no external security room shielding laser welding. The welding machine integrated with exhaust system, used for welding smoke and dust emissions.
Two spots of laser line welding machine adopts a welding instead of conventional resistance spot welding, torsional rigidity increased significantly. The same rhythm to the work, efficiency of the laser welding line is two times the resistance spot welding.
Laser remote welding speed is 5-8 times higher than the resistance spot welding, has the incomparable economic benefit in the welding of small parts, can be in many places in the application of body welding. Laser line resistance spot welder can used in the welding torch can be integrated to replace body, body lines and spot mixed production line.
Laser remote welding
Laser remote welding refers to large and focal length by tilting the beam (rather than by the welding speed of mobile laser fiber or parts) to realize welding the relative movement between the laser beam and workpiece.
Remote welding requires high beam quality. For BIW Welding the first laser CO2 laser is provided with a fixed scanner. With the development of fiber laser and other solid state laser beam quality improvement, can also be used together with smaller scanner, the scanner is installed on the 6 axis robots on the standard.
The use of two sets of system in the actual production, has very high productivity. Typical laser power is 4-6kW, the welding speed is 4-10m/ minutes. Stationary scanner can scan the maximum size for the work area 1.4m x 3m scanner, 1.6m focal length (Figure 1).
Figure 1.: wide format scanner (linear motor side to install a mirror scanner)
The work of the regional fixed large [1] scanner (3m x 1.4m x 0.4m /x, y, z)
Typical nugget by CO2- laser and fiber laser scanner to scan the wide, as shown in figure 2. The picture shows, the maximum possible fiber laser welding speed much higher. The reasons for this operation is 10.600 m (CO2- laser) and 1070nm (Yb doped fiber laser) laser radiation absorption mechanism is not the same. Due to longer wavelength, CO2- laser with plasma shielding effect, so that the upper seam is more wide, which reduces the penetration ability.
Figure 2:
Nugget lap welding. Material: low carbon steel DC04 plate thickness: 1mm
Laser power: 4.5kW
Left: fiber lasers: speed: 7m/ minutes
Right: CO2- laser: 3.6m/ minutes
In the actual welding parts, the processing time of Yb doped fiber laser welding parts required for a short time 30% than CO2- laser (Figure 3).
Parts:
Rear seat backrest with 45 welds
Rear seat backrest with CO2- and Yb doped fiber laser welding of 3:, laser power of two cases were 4.5kW
Some people have begun through the introduction of the beam quality is equal to or higher than 8mm without Ladd's high power solid state laser development of laser spot welding robot based on. The laser beam quality sufficient for 0.5m or longer working distance, and the guide system by optical fiber beam flexible, standard industrial robots can be used to set the scanner to move to a different location.
Also can use the robot with a constant velocity in the welding part mobile scanner, the scanner working area when the welded seam, can install the scanner to drop of welding using robot. This welding is called air welding, make up the installation type scanner work area smaller defects of robot, and increase the working space in the work area of the whole robot. The software package of support for these systems programming, help to optimize the robot trajectory and motion synchronization of robot and scanner.
However, because must be two different controller treatment: a robot controller and a scanner controller only by skilled operators for new component programming and operation of these devices. Only one controller solutions as shown in figure 4. This is a integrated tilt mirror robot, inclined mirror can make fast transverse and Z shaped mobile manipulator in inner. The controller of the robot is used to control the robot mechanical axis and optical component movement.
Laser remote welding, the main welding lap joint. For the welding of high quality, in the clamping connection part, clamping way should ensure welding between no air gap or the air gap is reduced to a minimum. Must use the same way, in order to be able to ensure that no gaps in all welding positions (cero gap) [please confirm. ] fixture. The applications in the fields of open standard hydraulic clamp conditions as shown in figure 5. Close the lid can be clamped, the laser beam through the holes on the lid into the.
For security reasons, laser remote welding is required to completely closed weld areas need to reciprocating movement to the inside of the shell parts. Only when fully closed shell and closed again to start the laser welding cycle electrical safety circuit. According to the technology and laser power, must use laser shell with a double wall structure and integrated optical sensor. This causes
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