Fiber laser welding system

Proposal of new manufacturing

26th Nov. 2011

AMADA Co., ltd

Product Concept
Process Range Expansion

Process Cost Reduction

Specification
Amada original head expand welding area Expand outside set up and easy inside set up

6-axis robot
(FANUC)

Original Head

Fiber laser
oscillator
(IPG,Max 6KW)

Weaving function
Beam rotate not robot moving This function cover the gap for stable welding and effective when use filler

CCD Camera unit

Peripheral equipment
Positioner table & traveling wagon

NC focus
control

Catch the path picture and compensate in TAS(teaching assist system) Clear picture can get because head position is the same by NC focus control

FLW_CAM New-AMNCTAS
FANUC latest NC controller makes easy set up and reduce teaching time by TAS(teaching support system) Check welding possibility in advance check the jig and device collision

Keep the nozzle gap and adjust the spot diameter for suitable welding condition

removable filler &

Gas nozzle Filler nozzle and side gas nozzle is movable Nozzle will avoid automatically if it is not use or touched

Co-axial shield gas nozzle

Welding regulation(direction etc) improved

Original Head
Integration of Beam quality and Amada welding technology
Hi Quality Weaving Function Rotate beam cover small gap and effect in filler welding

Robot
Automation/continuous operation NC Focus control -10mm +50mm Spot diameter change depend on robot position and surface
Filler nozzle Trailer nozzle

Easy operation Co-axial nozzle Beam and shield gas is the combined nozzle This nozzle cover all direction for easy operation

<Automation/continuous operation> Filler nozzle and trailer nozzle is movable Nozzle will avoid automatically if it is not use or touched

4 function to achieve concept

FLW_CAM
Make robot pass after check the head collision, Material suitable cutting condition set in advance and confirm by simulation

AMNC
Visual set up by FLW_CAM data Cutting condition setting Schedule function makes multi job operation
Get general 3D CAD data

TAS Teaching assist syatem

Adjust the simulation pass and actual pass. Camera system show the clear picture to adjust the pass compensation Original head Material welding condition & original head makes hi quality welding

Solid Works

FLW_CAM data is saved in database AMNC links the database Adjusted data in machine side also save in database

Developed amada original head

Sales Model
Model Standalone Model
Robot

FLW4000M3

Model Basic Model

Robot+Positioning Table
Robot Positioner Max weight 50kg Max weight 500kg

Model Traveling Wagon Model

(Robot+Positioning Table+ Traveling Wagon)

Traveling wagon

1.5m (standard)
W Amada original 650 SQ600Max lenght1500 (mm)

Oscilletor Welding head Max work size

Oscillator select from 2kw,4kw,6kw Model 3 standard traveling length is 1.5m, 3m and 6m is option Partition is standard
5

Fiber welding characteristic

Hi quality Hi speed
smooth and hi quality surface
Reduce finishing Reduce strain reduce burning

Hi speed by Hi power+CW

(In case of SUS304t2.0 or A5052t1.5 200mmx50mm corner welding)

210times speed compare with YAG,TIG 210times productivity(time) compare with YAG,TIG

Reduce running cost

Hi energy efficiency oscillator(3 times better than CO2, reduce electricity cost) Reduce optical consumption cost (In case of SUS304t2.0 or A5052t1.5 200mmx50mm corner welding) Running cost is the same as Tig1/41/10 of YAG

Difficult material welding

Hi reflect material(Al, Al alloy,copper etc) Cracky material (Al alloy,carbon alloy etc) Thick material(SS,SUS,AL etc) Welding difficult material(ZAM,Mg alloy,Titanium etc) Different material(SUS+Copper,SPCC+SECC,ZAS+SUS,FCD+S25C etc)
6

Utilize customers property

Data unification(3D,AP100,SDD,AMNC) Dedication for the customer who has F1,C1,HDS Shifting robot teaching process as external set up(programming) Existing 3D model,realizing it as external set up by assembly data Part location,assignment,robot motion creating is possible on the CG Modification is possible(Welding sequence,direction,grouping) Motion & collision check by real simulation

FLW-CAM

Sample comparison

Weld length 200mm (corner welding)

Fiber laser

SUS304 2.0
condition

50AF400 33sec JY4.9

400WF300 45sec JY33.4

4000WF2000 10sec JY7.4

time
Running cost Weld length 200mm (corner welding)

AL5052 1.5
condition time Running cost

80AF800 16sec JY 2.6

720WF300 45sec JY 87.3

4000W1500 12sec JY8.7

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high reflection material welding

Radiator plate
FLW4000M3
4kW Oscillator (YLS-4000-S2T)
Material, Thickness Part dimension Process speed Laser output process time

C1100(2t+2t+2t) 100806 F600 4000W 51 sec

process point
Location of brazing furnace fire pit is limited Fire pit brazing furnace is fit to mass production High reflection material welding is difficult
Fire pit brazing furnace
0

Productivity comparison
20

40

60

80

100

min 120

Process technology solution

Location free (Fire pit is not necessary) Various type Various LOT Welding reflection material by High output & high bright
Temporal weld

weld

Long length bundle process by traveling wagon

Bay window crest table with traveling wagon
Material, Thickness Part dimension Process speed Laser output process time

FLW4000M3
4kW Oscillator (YLS-4000-S2T)
SECC 0.8mm 140013040 F2000 2000W 1min 45 sec

process point
Joint part quality (Separating process)
0

Productivity comparison
20 40 60 90 120

min 150

Finishing (Deformation, burning, Filing) Thin thickness welding is difficult

Temporal weld Welding (TIG) Finishing
(Adjust deformation) (Clean burning) (Filing )

Process technology solution

Bundle process with traveling wagon Smooth bead, less deformation, less burning
Temporal weld weld

High output, Easy welding by CW

Deformation is improved drastically by Fiber laser

Semi-conductor device part

FLW4000M3
4kW Oscillator (YLS-4000-S2T)
Material, Thickness Part dimension Process speed Laser output process time

SUS430 1.2mm 1205060 F1000 1200W 30 sec

process point
Finishing (Deformation, burning, Filing ) Welding time Running cost
Temporal weld
0

Productivity comparison
10 20 30 40 50 60min

Welding (TIG)

Process technology solution

Smooth bead, less deformation, less burning High speed welding, temporal weld, shorter finishing time Electricity saving, no optical parts
Temporal weld weld

Finishing (Adjust deformation, Clean burning Filing )

Aluminum deformation is improved drastically

Power supply cover
FLW4000M3
4kW Oscillator (YLS-4000-S2T)
Material, Thickness Part dimension Process speed Laser output process time

A5052 2.0mm 25015060 F3000 2000W 1min 45 sec

process point
Adjacent hole of welding line is difficult Finishing (Deformation, burning, Filing) Aluminum welding is difficult
Temporal weld Welding (TIG) Finishing (Adjust deformation, Clean burning Filing )
0

Productivity comparison 10 20 30 40 50

min 60

Process technology solution

Possible to process by high beam quality, high output
Temporal weld weld

Smooth bead, less deformation, less burning

Aluminum welding by high output & CW