3D welding on-the-fly


With complete Cartesian calibration of the scan field and incorporated drift payment, even extremely position-critical welds can be made by scan heads at high speeds. Welding of heat exchangers for automobile exhaust devices comprises welding thin tubes to thin sheets on both ends. The elements are precision-stamped transparent wall parts, and the wick joint is a butt-edge weld where station fulfills the sheet at each end. A conventional setup is 16 tubes per cell case. Weil Engineering GmbH recognized that the ideal optic for laser welding these assemblies is a 2D scan source, which enables quick, precise positioning of the laser emission and has enough series of movement to bond the whole device without moving the optic and helmet.

The obstacle is finding the custom welding helmets the specifically at the crossway of television and sheet. The parts themselves are very repeatable-- Nevertheless, variation in the place of the assembly is higher than the repeatability needed for welding because of the tolerance stack-up of the tooling and indexing system. For that reason, correctly finding each assembly before welding was necessary.

The option was to include a camera-based vision system to discover essential tube sheet functions. This image is sent out to the Blackbird Robotics scanner controller (SCU), compared with the previously taped small assembly area and the scanner program is canceled out in x, y, and rotation around the z-axis to line up the welding course to the assembly's real position. This is all performed in under 300ms before welding of each assembly. These heat exchangers, in multiple-shift production given that 2012, were the very first application of this option. Ever since various 2D and 3D applications have made money from this mix of speed and precision.

Conntronic Prozess- und Automatisierungstechnik GmbH experienced the obstacle of welding the automated file module (ADM), which is a cooling real estate that supports VW's BlueMotion innovation efforts. BlueMotion is a variety of artistic energy-saving innovations, consisting of innovative engines that decrease fuel usage and hazardous emissions. The ADM is a complex mechanical real property that needs three various product densities to be assembled with an air-tight seal while lessening distortion. The business tried a variety of choice welding options, eventually choosing scanner-based remote laser welding due to the fact that of its capability to decrease robotic action. Along with its ability to only weld small diameter (6mm) circles and the full utility that long-focal-length optics offer less-restrictive tooling techniques.

The secrets to doing here were the Blackbird Robotics system's strong combination of the robotic instrument for programs, and once over the precision achieved through the 3D adjusted scan field and incorporated drift settlement of the galvanometers. The robotically installed intelliWELD scanner service from Blackbird Robotics has continued in production. 

Combining the speed and efficiency of a galvanometer-based scanner system with the changing variety of an articulated arm robotic can bring significant energy changes to remote welding purposes. When improving the flow of the scanner with the robotic, these gifts are made the most. With this arrangement, laser-on times of 90% or also can be recognized. Action has revealed that a particular weld using remote laser welding can be made in as low as 20% of the time required to make a similar weld using standard application up with approaches.

With individual buttons, on-the-fly welding can be executed in an extremely efficient way. State-of-the-art methods permit complete synchronization with the robotic transfer and supply an enhanced transmission capacity of the scan head and the robotic axes.