laser welding for automotive powertrain applications
DESCRIPTION
Production laser welding technology presents numerous benefits for productivity improvements in the manufacturing of automotive powertrain components. The laser welding production systems allow automated mass production joining of automotive powertrain components. Find out more at: http://www.emag.com/machines/applications/technologies/laser-welding/laser-welding-technology.htmlTRANSCRIPT
( © EMAG Automation GmbH, 2013 )Page 1
EMAG LASER SYSTEMS
for Powertrain Welding Applications
TEAM TLAS
( © EMAG Automation GmbH, 2013 )Page 2
TEAM TLAS
LASER WELDING – WHY?
■ enables size & weight reduction
■ replaces mechanical joints ( caulking, bolting )
■ enables new component designs using
material combinations (e.g. case hardening
steel / cast iron, steel / sheet metal )
■ suitable for high volume production ( takttime,
repeatability )
■ allows filler wire, e.g. suitable for cast iron /
steel welds
■ suitable for pre-assembled components
■ can integrate additional operations like laser
cleaning, assembling, pre- and postheating,
brushing. gaging/testing...
( © EMAG Automation GmbH, 2013 )Page 3
TEAM TLAS
ADVANTAGES OF LASER WELDING
■ Suitable for Powertrain Components
■ Depth & weld shape can be adapted to part
requirements
■ Very good weld quality
■ Allows filler wire, e.g. suitable for cast iron /
steel welds
■ Suitable for pre-assembled components like
diff cases
■ Additional operations like laser cleaning,
assembling, pre- and postheating, brushing
can be integrated.
■ Offers lower Cost per Piece compared to
Electron Beam Welding ( EBW )
( © EMAG Automation GmbH, 2013 )Page 4
TEAM TLAS
POWERTRAIN WELDING
Challenges:
■ Welding of finished components
■ More challenging materials
■ Process Monitoring
■ Process Integration
e.g. Assembling / Welding / Testing
General Aspects
Circular Welds
Penetration 2..8 mm
Typical Materials:
■ Case Hardening Steel
(e.g. 16MnCr5,20MnCr5, 25CrMo4)
■ Carbon Steel (e.g. C35)
■ Contruction St. (e.g. St52)
■ Cast Iron (GJS600 , GTS)
■ Low Carbon Sheets
( © EMAG Automation GmbH, 2013 )Page 5
TEAM TLAS
APPLICATIONS: DRIVEN GEARS ( Manual & Double-Clutch Transmissions)
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LASER WELDER FOR DRIVEN GEARS EMAG ELC160
Electrical Cabinet Chiller
Shield Gas
Delivery
Shield Gas
Delivery
Assembling / PressingAssembling / Pressing
Pre-HeatingPre-Heating
WeldingWelding Laser
Pneumatics
Purge Air
Pneumatics
Purge Air
( © EMAG Automation GmbH, 2013 )Page 7
TEAM TLAS
LASER WELDER FOR DRIVEN GEARS EMAG ELC160
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APPLICATION EXAMPLE: DRIVEN GEAR ( PASSENGER CAR )
Weld Dia. 53,5 mm
Material 16 MnCr5 ( both )
Pre-Heating not required
Penetration 2,5 mm (min)
Power ca. 2,0 kW
Cycle Time ( F2F ) < 8 sec
( © EMAG Automation GmbH, 2013 )Page 9
TEAM TLAS
APPLICATION EXAMPLE: DCT ( Double Clutch Transmission ) COMPONENTS
( © EMAG Automation GmbH, 2013 )Page 10
TEAM TLAS
ELC 160 POWERTRAIN WELDER
( © EMAG Automation GmbH, 2013 )Page 11
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PRINCIPLE ELC 160
3-Axis-Unit
( Spindle )
X/W/C
Welding Head
Upper Tooling
(Welding)Assembly Press
Options, e.g. Wire Brush,
Induction Coil ( Pre-Heating), Gaging, ...
( © EMAG Automation GmbH, 2013 )Page 12
TEAM TLAS
APPLICATION EXAMPLE: INPUT SHAFT FOR AUTOMATIC TRANSMISSION.
1. Pressing Shaft / Cup
2. Laser Welding Shaft/Cup
3. Laser Welding Cup / Ring
4. Turning of Face
5. Laser Welding Gear
6. Brushing
Cycle Time ~ 40 sec
Shaft
Ring
Gear
Cup
( © EMAG Automation GmbH, 2013 )Page 13
TEAM TLAS
EMAG HVSC 250 DUO
( © EMAG Automation GmbH, 2013 )Page 14
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PICKUP-MASCHINES
■ The Chuck „picks“ the parts off the conveyor
■ Handling & Automation is „integrated“
■ The part is moving, the „tool“ is fixed
■ Fixed Optics are much easier than „Flying“
Optics (Robustness, Ease of use, Tightness,
Optical...)
■ Less Tooling
■ Proven Concept for Mass Production
■ More expensive tooling, higher moving
masses
( © EMAG Automation GmbH, 2013 )Page 15
TEAM TLAS
APPLICATION EXAMPLE: LASER WELDING DIFFERENTIAL CASE / RING GEAR
The bolts between diff case and ring gear are
replaced by a laser welded joint.
Advantages:
■ Less Weight
■ Less Cost
■ Better Quality
( © EMAG Automation GmbH, 2013 )Page 16
TEAM TLAS
APPLICATION EXAMPLE: LASER WELDING DIFFERENTIAL CASE / RING GEAR
The Process:
■ Laser Cleaning of both components
■ Assembling / Pressing
■ Laser Welding
(Cast Iron / Case Hardening Steel,
with Filler Wire)
( © EMAG Automation GmbH, 2013 )Page 17
TEAM TLAS
APPLICATION EXAMPLE: LASER WELDING DIFFERENTIAL CASE / RING GEAR
Challenges:
■ Welding of Nodular Cast Iron and
Case Hardening Steel
An adapted welding process is required
■ Diff Case is pre-assembled and lubricated
( Risk of pollution in the weld zone )
Local cleaning prior to welding is required
■ Ring Gear is „finished“
Heat distortion must be improved
■ Ring may be phosphate coated
Local removal of phospate coating is required
( © EMAG Automation GmbH, 2013 )Page 18
TEAM TLAS
APPLICATION EXAMPLE: LASER WELDING DIFFERENTIAL CASE / RING GEAR
The Process:
■ Laser Cleaning
to remove pollution on the diff case
to remove phosphate coating on the
ring gear
■ Assembling / Pressing
■ Laser Welding
Cast Iron / Case Hardening Steel,
with Filler Wire)
■ (Brushing)
( © EMAG Automation GmbH, 2013 )Page 19
TEAM TLAS
LASER CLEANING
Before After
Laser Cleaning allows local, impact-free removal of
surface coatings and / or organic contamination
( © EMAG Automation GmbH, 2013 )Page 20
TEAM TLAS
LASER CLEANING
Surface
( © EMAG Automation GmbH, 2013 )Page 21
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LASER CLEANING OF DIFF.CASE
■ Rotational Cleaning ( EMAG )
■ Removal of any grease, oil etc. from the surface
■ Utilisation of the welding laser, no additional
laser is needed ( Time Sharing )
LASER BEAM
( © EMAG Automation GmbH, 2013 )Page 22
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WELD JOINT EXAMPLE
( © EMAG Automation GmbH, 2013 )Page 23
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TOOLING
■ Robust Welding Process
■ No tack weld required
■ Transmission is completely covered and protected
against weld spatter etc.
■ Automatic Changeover is available
Tooling Lower
Axial Force
(100kN max)
Pressing
Ring
Mandrel
LASER BEAM
( © EMAG Automation GmbH, 2013 )Page 24
TEAM TLAS
EMAG LASER CELL ELC 250DUO
■ Pickup Principle
■ 2 Stations
■ St.1: Laser Cleaning
■ St. 2: Laser Welding
■ Fixed Optics (Double)
■ Beam Switch
■ Integrated Press for Assembly and Clamping
( © EMAG Automation GmbH, 2013 )Page 25
TEAM TLAS
EMAG ELC 250 DUO
Laser
Chiller
Automation
Electrical
Slide ( 2* )
( © EMAG Automation GmbH, 2013 )Page 26
TEAM TLAS
EMAG ELC 250 DUO
( © EMAG Automation GmbH, 2013 )Page 27
TEAM TLAS
APPLICATION EXAMPLE : TRANSMISSION SHAFT
The Process:
■ Assembling
■ Pre-Heating ( Inductive )
■ Welding
■ Post-Heating
( © EMAG Automation GmbH, 2013 )Page 28
TEAM TLAS
APPLICATION EXAMPLE:
Link Shafts, Steering Shafts
( © EMAG Automation GmbH, 2013 )Page 29
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ELC 200 H: LASER WELDER FOR SHAFTS
■ Pickup
■ Fixed Optics
■ Flexible Automation
( © EMAG Automation GmbH, 2013 )Page 30
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EMAG ELC 200 H
( © EMAG Automation GmbH, 2013 )Page 31
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MULTI-KW LASERS FOR MATERIAL PROCESSING
Manufacturer
Wave Length
Max. Power
Investment / kW
Suitable for
Cutting
Heat Conduct. Welding
Key Hole Welding
Cladding
Laser Hardening
Brazing
Beam Delivery
Efficiency
CO2
Fast Flow
CO2
Diffusion
Cooled
Solid State
(Rod)
Solid State
( Disc )
Solid State
(Fibre)
Diode
Laser
Multiple ROFIN Multiple TRUMPF IPG Multiple
10,6 µm 10,6 µm 1,06 µm ~ 1,0 µm ~ 1,0 µm
0,808 µm
0,940 µm
max. 12 kW max. 6 kW max. 4,5 kW max. 8 kW max. 20 kW max. 5 kW
100% 90% 150% 130% 130% 80%
++ ++ o o o --
-- -- ++ ++ ++ +
++ ++ -- ++ ++ --
++ ++ ++ ++ ++ ++
+ + ++ ++ ++ ++
+ + + + + ++
Mirror Mirror Fiber Fiber Fiber
direct,
Fiber
8% 10% 4% 30% 30% 15%
( © EMAG Automation GmbH, 2013 )Page 32
TEAM TLAS
WHY EMAG?
■ EMAG is considered to be a technology leader
in the field of production systems
■ Only EMAG can offer such a wide portfolio of
technologies for powertrain components
■ EMAG ELC laser welders are installed major
OEM‘s and Tier 1 / 2 suppliers
■ EMAG ELC laser welders are designed for
volume production in terms of reliability and
performance.
■ EMAG offers turnkey solutions including
workholding, automation, process
and support.
■ EMAG has a global sales&service network and
is capable to support customers anywhere on
the planet.
( © EMAG Automation GmbH, 2013 )Page 33
TEAM TLAS
SUMMARY
■ Laser welding is used for a huge variety of
powertrain components
■ Production systems include numerous
peripheral processes like
laser cleaning, assembling, pre- / post-heating,
brushing, testing
■ Range of welded materials is increasing
■ Welding of finished components is a key for
flexible production
■ Solid State Lasers will gain significant market
share but require a lot of learning...
( © EMAG Automation GmbH, 2013 )Page 34
CONTACT
EMAG Holding GmbH
Austrasse 24
73084 Salach
Germany
Phone: +49 / 7162 / 17-0
Fax: +49 / 7162 / 17-199
www.emag.com