EMAG AUTOMATION LASER APPLICATION EXAMPLES
LASER WELDING SYSTEM FOR SUN GEARS ELC 160 Workpiece
Technological Features
»» Sun Gear
»» EMAG Laser Cleaning »» Two Processing Optics »» Workpiece Automation System incl. Turn Over Station »» EMAG Clamping Technology »» EMAG Ultrasonic Testing »» Laser Welding with Solid-State Laser
Layout Ultrasonic Testing
Processes Workpiece Handling Laser Cleaning
ELC 160 Joining and Laser Welding
Project Specifications Installation area Cycle time Changeover time 2
15 m x 8 m 45 seconds < 30 minutes
1
»» Loading of Individual Parts
2
»» Laser Cleaning
3
»» Joining
4
»» Laser Welding
5
»» Ultrasonic Testing
6
»» Unloading Finish Parts
LASER WELDING SYSTEM FOR DRIVEN GEARS ELC 160 HP Workpiece
Technological Features
»» Driven Gears
»» Eight different Workpieces can be manufactured without any Changeover ➙ One Piece Flow »» EMAG Ultrasonic Testing »» Integration of a Three-Zone Washing Machine »» Flexible but highly productive »» Welding Soft and Hard Gears
Layout
Stacker Unit for Synchronizer
2 x Ultrasonic Testing
Processes Loading Gears Pallet Transport System Brushing
Washing Machine
Unloading Finish Parts
ELC 160 HP
Project Specifications Installation area
16,3 m x 9,3 m
Cycle time
< 10 seconds
Changeover time
1
»» Loading of Individual Parts
2
»» Type and Position Inspection
3
»» Washing
4
»» Joining
5
»» Pre-Heating
6
»» Laser Welding
7
»» Marking
8
»» Brushing
9
»» Ultrasonic Testing
10
»» Unloading Finish Parts
no part change needed 3
LASER WELDING SYSTEM FOR DIFFERENTIALS ELC 250 DUO Workpiece
Technological Features
»» Differential
»» Highly productive Laser Welding Solution with a Cycle Time of only 28 Seconds »» EMAG Laser Cleaning
0,13 mm
1,67 mm
Diff case
4,25 mm
2,12 mm
»» ELC 250 DUO with two Laser Welding Stations, Laser Weld Monitoring and external Wire Stock
0,99 mm
Ring gear
»» Fully automated Axial Runout Measuring »» EMAG Ultrasonic Testing Equipment
0,33 mm
1,73 mm
1 mm
Layout
»» Laser Welding with Solid-State Laser
Processes ELC 250 DUO 2 x Laser Welding
Ultrasonic Testing
Loading / Unloading
Laser Cleaning
Axial Runout Measuring
Project Specifications
4
Installation area
10 m x 22 m
Cycle time
28 seconds
1
»» Loading of Individual Parts
2
»» Workpiece Detection via Data Matrix Code Camera
3
»» Laser Cleaning
4
»» Laser Welding
5
»» Axial Runout Measuring
6
»» Ultrasonic Testing
7
»» Unloading Finish Parts
LASER WELDING SYSTEM FOR STEERING PINIONS ELM Workpiece
Technological Features
»» Steering Pinion
»» Fully automated Laser Welding Solution with ELM-Machine »» EMAG Ultrasonic Testing Equipment »» Short Cycle Time < 10 Seconds »» EMAG Laser Cleaning
Layout
Workpiece Handling
Loading / Unloading Area
Ultrasonic Testing Laser
Laser Cleaning
Processes 1
»» Loading of Individual Parts
2
»» Laser Cleaning
3
»» Joining with ForceDisplacement Monitoring
4
»» Laser Welding
5
»» Ultrasonic Testing
6
»» Unloading Finish Parts
ELM Laser Welding Joining
Project Specifications Installation area
7,7 m x 6,3 m
Cycle time
< 10 seconds
5
LASER WELDING SYSTEM FOR DRIVEN GEARS ELC 160 HP Workpiece
Technological Features
»» Driven Gear
»» Fully automated Laser Welding Solution that eliminates Changeover Time »» Integration of a Three-Zone Washing Machine »» Welding hardened Components »» ELC 160 HP can weld up to five Components with no Changeover »» Double Gear (2nd + Reverse Gear) are joined, pre-heated and welded in one Operation »» Information about the Workpieces is recorded on a Chip in the Workpiece Carrier (RFID)
Layout Brushing
Ultrasonic Testing
Unloading Finish Part
Processes
ELC 160 HP Laser Welding
Washing Machine
Pallet Conveyor
Project Specifications Installation area Cycle time
10 seconds (double wheel 14 seconds)
Autonomy
50 workpieces
Changeover time 6
22 m x 9 m
15 minutes
1
»» Loading of Individual Parts
2
»» Washing
3
»» Joining
4
»» Pre-Heating in the ELC 160 HP
5
»» Laser Welding with Weld Seam Monitoring
6
»» Workpiece Cooling
7
»» EMAG Ultrasonic Testing
8
»» Brushing
9
»» Unloading Finish Parts
LASER WELDING SYSTEM FOR DIFFERENTIALS AND PTU‘S ELC 160 Workpiece
Technological Features
»» Differential
»» Fully automated Laser Welding System for small Differentials and PTU‘s
»» PTU
»» EMAG Laser Cleaning Equipment »» EMAG Ultrasonic Testing Equipment »» Laser Welding with Solid-State Laser
Layout
Axial Runout Measuring
Processes
Ultrasonic Testing Loading / Unloading
1
»» Individual Parts Loaded on Pallets
2
»» Laser Cleaning
3
»» Joining Station
4 Laser Cleaning
Brushing ELC 160 Laser Welding
Joining
Project Specifications Installation area
5
»» Brushing
6
»» Ultrasonic Testing
7
»» Axial Runout Measuring System
8
»» Unloading Finish Parts
13 m x 10 m
Cycle time
27 seconds
Autonomy
endless
Changeover time
»» Laser Welding with Weld Seam Detection and Process Monitoring
25 minutes 7
LASER WELDING SYSTEM FOR CV JOINTS ELC 160 HP Workpiece
Technological Features
»» CV Joint
»» Laser Welding of three different Components in one Operation »» Capable of machining different Materials (high carbon steel / low carbon steel) »» Laser Marking »» Laser Welding with Solid-State Laser and Automation »» Laser Welding is monitored with Plasma-, Temperature-, Laser Power Measurement and Crosshair Camera
Layout
Processes ELC 160 HP Marking Station
Chiller
1
»» Loading of Individual Parts
2
»» Laser Marking
3
»» Laser Welding
4
»» Unloading Finish Parts
Loading System
Laser Pallet Transport System
ELC 160 HP Laser Welding
Project Specifications Installation area Cycle time
15 seconds
Autonomy
20 workpieces (5 minutes)
Changeover time 8
11,5 m x 2,9 m
no changeover needed
LASER WELDING SYSTEM FOR DRIVEN GEARS ELC 160 HP Workpiece
Technological Features
»» Driven Gear
»» Fully automated Laser Welding System for Driven Gears »» Integration of Automation and Robot Handling »» Laser Welding with Solid-State Laser
Layout
Laser Marking
Processes
ELC 160 HP Laser Welding
Stacker Unit for Synchronizer
Brushing
1
»» Loading of Individual Parts
2
»» Type & Position Control
3
»» Joining with ForceDisplacement Monitoring
4
»» Laser Marking
5
»» Laser Welding, Process Sensors, Edge Detection with WeldMaster, Crosshairs Camera, Laser Power Measurement
6
»» Brushing
7
»» Palletizing of Finish Parts
Palletizer
Project Specifications Installation area
ca. 8,6 m x 9,2 m
Cycle time
11 seconds
Autonomy
40 minutes
Changeover time
within the series 1-3 / 4-7 without changeover 9
LASER WELDING SYSTEM FOR DUAL MASS FLYWHEELS ELC 160 Workpiece
Technological Features
»» Dual Mass Flywheel
»» Laser Welding of pre-assembled Parts »» Integrated Leak Test Station »» Two fully automated Laser Welding Machines
Layout
ELC 160 Joining and Laser Welding OP20
Leak Testing
ELC 160 Joining and Laser Welding OP10
Finish Parts
Workpiece Handling
Project Specifications Installation area Cycle time
27 seconds
Autonomy
60 minutes
Changeover time 10
11,5 m x 7,5 m
program selection
Processes 1
»» Loading of Individual Parts
2
»» Joining, Detecting and Laser Welding OP10
3
»» Leak Testing
4
»» Infeed of Sprockets
5
»» Joining, Detecting and Laser Welding OP20
6
»» Unloading Finish Parts
LASER WELDING SYSTEM FOR DIFFERENTIAL CASES ELC 160 Workpiece
Technological Features
»» Differential Case
»» Integration of an ABB Handling Robot »» 200 kN Press Station »» EMAG Laser Cleaning »» Round and Axial Runout Measurement »» Welding Process is monitored by Plasmo »» Trumpf Welding Optics »» Welding Operation with Filler Wire
Layout
Laser Cleaning
Processes
Brushing
ELC 160 Laser Welding DMC Reading
Pallet Conveyor
Joining
Measuring Station
Robot Handling
1
»» Loading of Individual Parts
2
»» DMC Reading
3
»» Laser Cleaning
4
»» Joining
5
»» ELC 160 Laser Welding
6
»» Brushing
7
»» Measuring
8
»» Unloading Finish Parts
Project Specifications Installation area Autonomy
10 m x 9 m 5 workpieces
11
LASER WELDING SYSTEM FOR STEERING SHAFTS ELC 160 WITH TWO SLIDES Workpiece
Technological Features
»» Steering Shaft
»» Alternative to Friction Welding and Magnet Arc Welding »» Steel Shafts (e.g. Drive Shafts, Prop Shafts, Steering Shafts) »» Aluminium Shafts (e.g. Steering Shafts) »» Workpiece of up to 1,000 mm in Length »» Two Slide Machine (the machine is loaded and unloaded to the right and left of the welding center) »» Pre-Heating and Post-Heating »» Weld-Seam Position is detected by a Camera System »» TWIN-Spot Optics »» Laser Welding with Solid-State Laser
Layout ELC 160 Laser Welding
Loading / Unloading 2
Loading / Unloading 1
Project Specifications Installation area Cycle time
from 30 seconds
Autonomy
- (hand loaded)
Changeover time 12
10 m x 5 m
15 minutes
Processes 1
»» Loading of Individual Parts
2
»» Turn Components into Correct Rotational Position
3
»» Pre-Heating
4
»» Laser Welding with Protection Gas and Filler Wire including Precitec LWM and Weld Seam Finder
5
»» Post-Heating
6
»» Unloading Finish Parts
LASER WELDING SYSTEM FOR DRIVEN GEARS ELC 160 HP Workpiece
Technological Features
»» Driven Gear
»» Workpiece Detection »» Welding Optics YW52 with LWM Sensor Module that includes Plasma and Temperature Detectors from Precitec »» EMAG Ultrasonic Testing
Layout
Workpiece Detection
ELC 160 HP Joining and Laser Welding
Brushing Brushing and Ultrasonic Testing
Processes 1
»» Loading of Individual Parts
2
»» Workpiece Detection by Camera
3
»» Joining with ForceDisplacement Monitoring
4
»» Laser Welding
5
»» Brushing
6
»» Ultrasonic Testing
7
»» Unloading Finish Parts
Project Specifications Installation area
5,6 m x 10,8 m
Cycle time
≈10 seconds
Autonomy
5 minutes
Changeover time
5-10 minutes 13
LASER WELDING SYSTEM FOR CAMSHAFT ADJUSTERS ELC 160 Workpiece
Technological Features
» Camshaft Adjuster
» Thermal Joining and Laser Welding in one Project » Welding of Forged and Sintered Components » Workpiece Detection by a Camera System
Layout ELC 160 Laser Welding
Processes
Joining Robot Handling
Unloading Finish Parts
Brushing and Oiling
Loading of Individual Parts
Project Specifications Installation area Cycle time
34 seconds
Autonomy
15 minutes
Changeover time 14
6mx6m
8 minutes
1
» Orientation and DMC Reading
2
» Alignment of the Shafts
3
» Heating Camshaft Adjuster
4
» Joining
5
» Laser Welding
6
» Brushing
7
» Oiling
8
» Unloading Finish Parts
LASER WELDING SYSTEM FOR PISTON FOR TORQUE CONVERTER ELC 160 DUO Workpiece
Technological Features
»» Piston for Torque Converter
»» EMAG Clamping Technology »» One Laser Source for two Stations
Layout
CO2 Laser
ELC 160 DUO (2x Laser welding)
1
»» Loading of Individual Parts
2
»» Clamping of Individual Parts
3
»» Laser Welding with CO2 Laser
4
»» Unloading Finish Parts
Manual Loading / Unloading
Project Specifications Installation area
6,2 m x 3,4 m
Cycle time
22,5 seconds
Changeover time
Processes
about 10 minutes
15
LASER WELDING SYSTEM FOR DOUBLE CLUTCH COMPONENTS ELM Workpiece
Technological Features
»» Double Clutch Components
»» Laser Welding System with ELM for Double Clutch Components »» EMAG Laser Cleaning »» EMAG ELM Laser Module »» Laser Welding with Solid-State Laser
Layout
Pallet Transport System
Loading / Unloading
Laser Cleaning
Workpiece Handling
ELM Laser Welding
Project Specifications Installation area Cycle time Changeover time
16
9,5 m x 5,4 m 19,6 seconds (ELM ca. 10 seconds) <10 minutes
Brushing
Processes 1
»» Loading of Individual Parts
2
»» DMC Code Reading
3
»» Laser Cleaning
4
»» Laser Welding
5
»» Brushing
6
»» Unloading Finish Parts
LASER WELDING SYSTEM FOR DCT AND AT COMPONENTS ELC 160 Workpiece
Technological Features
»» Double Clutch
»» Universal Machine Concept for Double Clutch and Automatic Transmission Components »» Automation can be easily configured with the Laser Welding, Turning and Brushing Process »» Laser Welding with Solid-State Laser
Layout
Processes
Brushing Station
Joining Station
Workpiece Handling
1
»» Loading of Individual Parts
2
»» Laser Welding with Process Monitoring
3
»» Automated Brushing of the Welded Surface
4
»» Unloading Finish Parts
ELC 160 Laser Welding
Project Specifications Installation area Cycle time Changeover time
ca. 6,2 m x 2,6 m 30 seconds no changeover needed 17
LASER WELDING SYSTEM FOR PLANETARY CARRIER COMPONENTS ELM Workpiece
Technological Features
»» Planetary Carrier
»» Special EMAG Clamping Fixture »» Components are aligned in the Clamping Fixture »» EMAG Laser Cleaning »» Segment Welding »» EMAG Ultrasonic Testing
Processes
Clamping Fixture
Piston Shaft
Hirth Cuppling
Project Specifications
18
Cycle time
24 seconds
Autonomy
45 minutes
1
»» Loading of Individual Parts
2
»» Laser Cleaning
3
»» Positioning of the Components
4
»» DMC Reading
5
»» Laser Welding
6
»» Brushing
7
»» Ultrasonic Testing
8
»» Unloading Finish Parts
LASER WELDING SYSTEM FOR PLANETARY CARRIER COMPONENTS 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
Processes
Layout Workpiece Handling with Robot
Unloading Finish Part
ELC 160 Pre-Heating and Laser Welding
1
»» Loading of Individual Parts
2
»» Workpiece Handling by a Robot
3
»» DMC Code Reading
4
»» Pre-Heating
5
»» Laser Welding including Process Monitoring
6
»» Unloading Finish Parts
Project Specifications Loading Workpiece with Automated Washing Machine
DMC Reading
Installation area Cycle time Changeover time
8mx5m 32 seconds 9 minutes
19
LASER WELDING SYSTEM FOR DRIVE SHAFTS ELM 250 Workpiece
Technological Features
» Drive Shaft
» Rotary and Positioning Axis » Laser Welding with Solid-State Laser » Laser Welding of non-automotive Parts
Seam 1
Seam 2
Layout
ELM Laser Welding
Rotary Table 180° with two Stations Assembly Endpiece 2 Robot Handling Assembly Endpiece 1
Loading Endpieces Loading Segment
Project Specifications Installation area Cycle time
12 seconds
Autonomy
60 minutes
Changeover time 20
7,5 m x 5,5 m
no changeover needed
Processes 1
» Loading of Individual Parts
2
» Assembly of Individual Parts for Welding Components
3
» Workpiece Handling by a Robot
4
» Laser Welding with Process Monitoring
5
» Handling Finish Parts by a Robot
6
» Unloading Finish Parts
LASER WELDING SYSTEM FOR ROTOR SHAFTS ELC 160 Workpiece
Technological Features
» Rotor Shaft
» Two Processing Optics » Inductive Pre-Heating » I nformation about the Workpiece is recorded on a Chip in the Workpiece Carrier (RFID) » Process Data Archiving (EMAG Data Recorder) » Laser Welding with Solid-State Laser » Laser Welding System for Electric Drives
Seam 1
Seam 2
Processes
Layout ELC 160 Laser Welding
Ultrasonic Testing
Measuring Station
Laser Marking
Pressing Station
Conservation
Laser Cleaning
Pallet Transport System
1
» Loading of Individual Parts
2
» Type & Position Control
3
» Laser Cleaning
4
» Laser Welding with Process Monitoring
5
» Ultrasonic Testing
6
» Measuring
7
» Laser Marking
8
» Conservation Finish Parts
9
» Unloading Finish Parts
Project Specifications Installation area
13 m x 8,5 m
Cycle time
33 seconds
Autonomy
10 minutes
Changeover time
no changeover needed 21
LASER WELDING SYSTEM FOR MAIN HUBS ELC 160 Workpiece
Technological Features
» Main Hub
» W elding of four Single Components with two Slides and two Optics in one Machine » Two Welding Heads for Axial and Angular Welding » Axial and Radial Alignment of the Components » EMAG Clamping Technology
Layout
Processes Workpiece Handling Brushing
Laser Cleaning
Pallet Transport System
Project Specifications Installation area Cycle time
22
12,1 m x 7,1 m 58,8 seconds
ELC 160 Laser Welding
1
» Loading of Individual Parts
2
» DMC Marking
3
» Laser Cleaning
4
» Positioning of the Components
5
» Laser Welding
6
» Brushing
7
» Unloading Finish Parts
LASER WELDING SYSTEM FOR STEEL PISTONS ELC 160 Workpiece
Technological Features
» Steel Pistons
» Laser Cleaning » Joining » Laser Welding with Precitec LWM and WeldMaster » Automation » Clamping Technology » Laser Welding with Solid-State Laser
Source: Mahle
Layout
Processes Pre-Heating and Joining
Pre-Heating before Welding
Workpiece Handling
Cooling
ELC 160 Laser Welding
Project Specifications Installation area
» Loading of Individual Parts
2
» Laser Cleaning
3
» Pre-Heating (before Joining)
4
» Heating (before Welding)
5
» Laser Welding
6
» Post Heat Treatment
7
» Cooling
8
» DMC Reading and Orientation
9
» Unloading Finish Parts
16 m x 8,5 m
Cycle time
24 seconds
Autonomy
endless
Changeover time
Robot Handling
1
60 minutes 23
EMAG Salach GmbH Salach Austrasse 24 73084 Salach Germany Phone: +49 7162 17-0 Fax: +49 7162 17-4027 E-mail: info@salach.emag.com
Munich Zamdorferstrasse 100 81677 München Germany Phone: +49 89 99886-250 Fax: +49 89 99886-160 E-mail: info@muenchen.emag.com
Frankfurt Martin-Behaim-Strasse 12 63263 Neu-Isenburg Germany Phone: +49 6102 88245-0 Fax: +49 6102 88245-412 E-mail: info@frankfurt.emag.com
Austria Glaneckerweg 1 5400 Hallein Austria Phone: +43 6245 76023-0 Fax: +43 6245 76023-20 E-mail: info@austria.emag.com
Leipzig Pittlerstrasse 26 04159 Leipzig Germany Phone: +49 341 4666-0 Fax: +49 341 4666-114 E-mail: info@leipzig-emag.com
Denmark Horsvangen 31 7120 Vejle Ø Denmark Phone: +45 75 854854 Fax: +45 75 816276 E-mail: info@daenemark.emag.com
Hungary Gerenda 10 1163 Budapest Hungary Phone: +36 30 9362-416 E-mail: lbujaki@emag.com Czech Republic Lolkova 766 103 00 Praha 10 – Kolovraty Czech Republic Phone: +420 731 476070 E-mail: mdelis@emag.com Poland ul. Krzycka 71A / 6 53-020 Wrocław Poland Phone: +48 728 389 989 E-mail: info@poland.emag.com Turkey Sanayi Cad. No.: 44 Nish İstanbul Sitesi D Blok D: 155 Yenibosna – Istanbul Turkey Phone: +90 532 694 54 44 E-mail: ckoc@emag.com
Sweden Glasgatan 19B 73130 Köping Sweden Phone: +46 221 40305 E-mail: info@sweden.emag.com
Market Companies EUROPE
AMERICA
ASIA
EMAG MILANO Srl Via dei Mille 31 20098 San Giuliano Milanese (Mi) Italy Phone: +39 02 905942-1 Fax: +39 02 905942-24 E-mail: info.milano@emag.com
EMAG L.L.C. USA 38800 Grand River Avenue Farmington Hills, MI 48335 USA Phone: +1 248 477-7440 Fax: +1 248 477-7784 E-mail: info@usa.emag.com
NODIER EMAG INDUSTRIE S.A.S. 5 Avenue de L‘Europe – BP 22 18150 La Guerche sur L‘Aubois France Phone: +33 248 7711-00 Fax: +33 248 7111-29 E-Mail: info@nodier.emag.com
EMAG MEXICO Maquinaria EMAG Mexico S de RL de CV Av. Hercules 301 Nave 1 Poligono Empresarial Santa Rosa 76220 Santa Rosa Jauregui, Querétaro Mexico Phone: +52 442 291 1552 E-mail: info.mexico@emag.com
EMAG (China) Machinery Co., Ltd. Building A3 & B7 Cangneng Europe & America Technology Park No. 8 Loujiang Rd. (N.) 215400 Taicang Jiangsu, China Phone: +86 512 5357-4098 Fax: +86 512 5357-5399 E-mail: info@emag-china.com
EMAG MILANO Srl Sucursal en España Pasaje Arrahona, n° 18 Polígono Industrial Santiga 08210 Barberà del Vallès (Barcelona) Spain Phone: +34 93 7195080 Fax: +34 93 7297107 E-mail: info.spain@emag.com EMAG UK Ltd. Chestnut House, Kingswood Business Park Holyhead Road Albrighton Wolverhampton WV7 3AU Great Britain Phone: +44 1902 37609-0 Fax: +44 1902 37609-1 E-mail: info@uk.emag.com
EMAG DO BRASIL Edifício Neo Corporate Offices, CJ 1503 Rua Enxovia, 472 04711-030 São Paulo SP Brazil Phone: +55 11 38370145 Fax: +55 11 38370145 E-mail: info@brasil.emag.com
EMAG KOREA Ltd. Rm204, Biz center, SKn Technopark, 124 Sagimakgol-ro, Sangdaewon-dong, Jungwon-gu, Seongnam City, Gyeonggi-do, 462-721 South Korea Phone: +82 31 776-4415 Fax: +82 31 776-4419 E-mail: info@korea.emag.com
EMAG (Chongqing) Machinery Co., Ltd. No. 10th Lailong Road Yongchuan District 402160 Chongqing China Phone: +86 23 49783399 Fax: +86 23 49783388 E-mail: info@emag-china.com TAKAMAZ EMAG Ltd. 1-8 Asahigaoka Hakusan-City Ishikawa Japan, 924-0004 Japan Phone: +81 76 274-1409 Fax: +81 76 274-8530 E-mail: info@takamaz.emag.com EMAG INDIA Pvt. Ltd. Technology Centre No. 17/G/46-3, Industrial Suburb, 2nd Stage, Yeshwantpur, Bengaluru – 560 022. India Phone: +91 80 50050163 E-mail: info@india.emag.com
EMAG OOO ul. Akademika Chelomeya 3/2 117630 Moscow Russia Phone: +7 495 287 0960 Fax: +7 495 287 0962 E-mail: info@russia.emag.com
www.emag.com 24