EMAG LASERTEC APPLICATION EXAMPLES 2.0
LASER WELDING SYSTEM FOR PLANETARY CARRIER ELC 160 Workpiece
Technological Features
» Planetary Carrier
» Transmission Shaft with Planetary Carrier and integrated Parking Lock » A Parking Lock needs Induction Hardening » High Carbon Content makes Laser Welding difficult » EMAG developed a Laser Welding Process with integrated Pre-Heating to overcome existing Crack Problems Micrograph of the Welding Seam
Layout
Unloading Finished Parts
Robot
ELC 160 Induction Pre-Heating and Laser Welding
Processes 1 2 3 4 5 6
Loading Workpiece through Washing Machine
DMC-Reading Station
Project Specifications Installation area Cycle time Changeover time 2
8mx 5m 33 Seconds 9 Minutes
» Loading of Individual Parts » Workpiece Handling by a Robot » DMC-Reading » Induction Pre-Heating » Laser Welding » Unloading Finished Parts
LASER WELDING SYSTEM FOR TRUCK DIFFERENTIAL ELC 600 Workpiece
Technological Features
» Truck Differential
» Workpieces up to 130 kg » Workpiece Diameter up to 600 mm » Two Welding Seams on one Workpiece » Weld Seam from 90° Radial to 45° Axial » Joining and Holding Forces up to 100 kN » Integrated Torque Testing of the Differential (Possible before and after Welding)
Truck Differential
Layout Loading
Passenger Car Differential (for comparison)
Processes
LC 8 Laser Cleaning Joining Torque Testing
Unloading
Induction Pre-Heating
Ultrasonic Testing
ELC 600 Laser Welding
1
» Pre-Assembly of the Differential (by the Customer)
2
» Part Handling with Conveyor Units / Robots
3
» Laser Cleaning of Cover, Housing and Ring Gear
4
» Induction Pre-Heating (for forcefree assembly of Ring Gear)
5
» Joining
6
» Laser Welding with Integrated Torque Testing
7
» Ultrasonic Testing of both Weld Seams
8
» Assembly
9
Project Specifications Installation area
16 m x 9 m
Cycle time
108 Seconds
» Unloading Finished Parts
3
LASER WELDING SYSTEM FOR CLUTCH PARTS ELC 160 Workpiece
Technological Features
» Main Hub
» EMAG Laser Cleaning » Welding of four single Components with three Welding Seams » Two XCW Slides, two Joining Stations, three Welding Stations in ELC 160 » Two Welding Heads for Axial and Angular Welding » EMAG Clamping Technology
Micrographs of the Welding Seams
Layout
ELC 160 Laser Welding
Laser Source
DMC-Marking
Brushing
LC 4-2 Laser Cleaning
Project Specifications Installation area Cycle time Changeover time 4
7.5 m x 10 m 66 Seconds 5 Minutes
Processes 1
» Laser Cleaning (manually loaded)
2
» Loading of Individual Parts
3
» Joining
4
» Laser Welding
5
» Brushing
6
» DMC-Marking
7
» Unloading Finished Parts
LASER WELDING SYSTEM FOR DRIVEN GEARS ELC 160 HP Workpiece
Technological Features
» Driven Gears
» EMAG Laser Cleaning » Type and Position Inspection » Pre-Heating of the Components with UMH Technology » EMAG Ultrasonic Testing » Three different Ultrasonic Heads can be used without any Changeover time » Fourteen different Types of Workpieces
Layout
UT 4 Ultrasonic Testing
UMH Pre-Heating
Brushing Station ELC 160 HP Joining and Laser Welding Camera Station
Cooling tunnel SPC Loop LC 4 Laser Cleaning
Mandrel storage
Cycle time Changeover time
1
» Laser Cleaning
2
» External Press for Dual Gears
3
» Joining Clutch Rings
4
» UMH Pre-Heating
5
» Laser Welding
6
» Workpiece Cooling
7
» Brushing of the Welding Seam
8
» Ultrasonic Testing
9
Project Specifications Installation area
Processes
» Laser Marking
11.3 m x 9.8 m 11 Seconds 5 Minutes 5
LASER WELDING SYSTEM FOR PASSENGER CAR DIFFERENTIAL ELC 160 Workpiece
Technological Features
» Passenger Car Differential
» Fully automated Laser Welding System for Passenger Car Differential » EMAG Laser Cleaning » EMAG Ultrasonic Testing » Laser Welding with Solid-State Laser » Axial and radial Weld Seams integrated in one System
Layout Joining Station
Processes ELC 160 Laser Welding
1 Ultrasonic Testing
LC 4-2 Laser Cleaning
2 3 4 5 6 7
Pallet Transport System
Brushing Station
Project Specifications Installation area Cycle time Changeover time 6
14.7 m x 6.7 m 35 Seconds ca. 30 Minutes
» Loading of Individual Parts » Laser Cleaning » Joining » Laser Welding » Brushing » Ultrasonic Testing » Unloading Finished Parts
LASER WELDING SYSTEM FOR PASSENGER CAR DIFFERENTIAL ELC 160 Workpiece
Technological Features
» Passenger Car Differential
» EMAG Laser Cleaning » EMAG Ultrasonic Testing » Laser Welding with Solid-State Laser » Differential and Intermediate Shaft of electric drive unit without change-over
Layout Joining Station
Processes ELC 160 Laser Welding
1 Laser Source
3
LC 4-2 Laserreinigen
Loading / Unloading
2
Brushing Station
» Loading of Individual Parts » Laser Cleaning » Joining
4
» Laser Welding
5
» Brushing
6
» Ultrasonic Testing
7
» Unloading Finished Parts
Ultrasonic Testing
Project Specifications Installation area Cycle time Changeover time
12 m x 7.9 m 30 Seconds ca. 30 Minutes 7
LASER WELDING SYSTEM FOR SHAFT PARTS ELC 160 HP Workpiece
Technological Features
» Shaft Parts
» EMAG Laser Cleaning » Joining Force in the Machine up to 50kN » EMAG developed a Laser Welding Process with integrated Pre-Heating to overcome existing Crack Problems » High Production Volume
Layout
Processes ELC 160 HP Joining, Induction Pre-Heating and Laser Welding
1 2 3 4 5 6
Loading / Unloading
Project Specifications Installation area Cycle time 8
LC 4-2 Laser Cleaning
9.6 m x 6.4 m 12 -18 Seconds
» Loading » Laser Cleaning » Joining » Induction Pre-Heating » Laser Welding » Unloading Finished Parts
LASER WELDING SYSTEM FOR CAMSHAFTS ELC 160 Workpiece
Technological Features
» Camshaft
» Fully automated Feed and Discharge of Individual Parts and Finished Parts » Vision Systems for Detection and Position Orientation » EMAG Induction Pre-Heating Technology » Force and Path monitored Joining Process » 100% Post-Process Measurement Q-Characteristics » Assembly of additional Elements
Layout DMC-Reading, Pre-Orientation Camshaft Adjuster
Processes
Delivery Camshaft Adjuster
1 Delivery Camshaft
CO2 Laser Source
Chiller
Induction PreHeating Camshaft Adjuster
Measuring Station
Project Specifications Cycle time Changeover time
» Delivery Shaft from Basket Stacker Unit
3
» Orientation, DMC- Reading Camshaft Adjuster
4
» Induction Pre-Heating Camshaft Adjuster » Orientation Camshaft, DMCReading and Joining » Laser Welding
Pressing, Brushing, DMC-Marking
ELC 160 Laser Welding
Installation area
2
5
Orientation, DMCReading, Joining Camshaft
» Feeding Camshaft Phaser on pallet
Oiling Station Stacking Finish Parts 13 m x 10 m 24.5 Seconds 10 Minutes
6 » Measuring Angle and Position 7 8
» Assembling Sealing Caps, Brushing, DMC Laser Marking
9
» Oiling Welding Seam
10
» Stacking Finished Parts in Basket Stacker Unit 9
LASER WELDING SYSTEM FOR ALUMINUM AIR-CONDITIONING PIPES ELC Workpiece
Technological Features
» Aluminum Air-Conditioning Pipes
» Alternative to Soldering » Aluminum Welding with Filler Wire » Five Welding Seams per Workpiece » Seam Scan with EMAG EC Seam » Loading and Unloading during Machining » Workpiece Length up to 1.200 mm
Layout
Processes
Weld Fume Extraction
Laser Welding
1 2 3
Loading / Unloading
Project Specifications Installation area (inklusive Laser und Kühler) Cycle time (bei 5 Schweißnähten) 10
4.3 m x 4.6 m 40 Seconds
» Loading of Individual Parts » DMC-Reading » Laser Welding
4
» Scanning of the Welding Seam with Position Detection and Control
5
» Unloading Finished Parts
LASER WELDING SYSTEM FOR OUTPUT SHAFTS ELC Workpiece
Technological Features
» Output Shaft
» Seam Scan with EMAG EC Seam » Loading and Unloading during Machining » Workpiece Length up to 450 mm
Layout
Weld Fume Extraction
Laser Welding
Processes 1 2
Solid-State Laser Source
» Loading of Individual Parts » Induction Pre-heating
3
» Seam detection EC Seam
5 4
» Laser Welding
5
» Unloading Finished Parts
Loading / Unloading
Project Specifications Installation area
4.7 m x 4 m
Cycle time
16 Seconds 11
LASER CLEANING SYSTEM FOR FIXED OUTER RACE LC 4-2 Workpiece
Technological Features
» Fixed Outer Race
» Pulsed Fiber Laser: 200 Watt » Less Energy Consumption than Conventional Washing Machines » No additional Contamination by Washing Detergent Residues » Laser Marking as an additional Function » Can be used as Standalone Solution or fully automated » Multiple Fields of Application: - Removal of Organic Substances as Preparation for Laser Welding - Removal of Paint Layer or other Coatings
Layout
Control Panel
Laser Cleaning
Processes 1 2 3
Loading / Unloading
Integrated Fiber Laser Source
Project Specifications
12
Installation area
3 m x 1.5 m
Cycle time
20 Seconds
» Loading of Individual Parts » Laser Cleaning » Unloading Finished Parts
JOINING SYSTEM FOR CAMSHAFTS 2 X SFC 400 Workpiece
Technological Features
» Camshaft
» Joining of precise Components without reworking » Workpiece Length up to 600 mm » Pyrometric Temperature Test » EMAG Induction Pre-Heating Technology
Layout
Processes Joining
Pre-Heating
Pallet Removal
Joining
Pre-Heating
1
» Pallet Conveyor
2
» Induction Pre-Heating
3
» Reference Measurement
4
» Joining
5
» Final Measurement
6
» Pallet Removal
Pallet Conveyor
Project Specifications Installation area Cycle time
10.6 m x 5.9 m 28 Seconds 13
JOINING STATION FOR CAMSHAFTS VA 700 T Workpiece
Technological Features
» Camshafts
» Fully automated Joining Process via NC controlled Linear Unit » EMAG Induction Pre-Heating Technology
Layout
Processes
Induction Pre-Heating
1 Delivery Cam Pieces
2 3
Delivery Shafts
Joining
Project Specifications Installation area Cycle time 14
Unloading Finished Parts 10.5 m x 2.6 m 74 Seconds
4
» Loading of Individual Parts » Induction Pre-Heating » Joining » Unloading Finished Parts
JOINING STATION FOR ROTOR SHAFTS Workpiece
Technological Features
» Rotor Shaft
» Workpiece Length up to 450 mm » Workpiece Diameter up to 250 mm » Automatic Orientation of the Individual Parts » Dynamic, pyrometer controlled Inductive Heating of Rotor Package (inside and outside) » Force and Path monitored Joining Process » Force controlled Pressing during Shrinking
Layout
SPC / NOK Drawer
Processes
Robot
Orientation and Joining DMC-Reading Shaft
Cooling Tunnel
1
» Automatic Delivery of Shaft and Rotor Package
2
» Orientation and DMC Reading Shaft
3
» Induction Pre-Heating Rotor Package
4
» Joining Shaft in Rotor Package
5 Delivery Rotor Package
6
» Cooling Finished Parts » Unloading Finished Parts
Induction Pre-Heating Delivery Shaft
Robot
Project Specifications Installation area
5 m x 14 m
Cycle time
55 Seconds 15
JOINING STATION FOR ROTOR SHAFTS Workpiece
Technological Features
» Rotor Shaft
» Workpiece Length up to 450 mm » Workpiece Diameter up to 250 mm » Dynamic, pyrometer controlled Inductive Heating of Rotor Package (inside and outside) » Cycle time neutral Loading and Unloading of the Joining Station through Shuttle Operation » Force and Path monitored Joining Process » Freely programmable Positioning of the Shaft » Force controlled Pressing during Shrinking to control Deformation
Layout
Processes Laser Marking Joining
Induction Pre-Heating
1 2 3 4 5
Robot
Project Specifications Installation area Cycle time 16
Conveyor Belt (Customer Provision) 5.8 m x 5.1 m 60 Seconds
» Loading of Individual Parts » Induction Pre-Heating » Joining » Laser Marking » Unloading Finished Parts
17
Turning
Milling
Grinding
Gear Hobbing
Power Skiving
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