Combination scheme from cutting to laser processing

In the past few years, the significance of laser welding in the field of workpiece connection has become increasingly important. In general, the components connected by laser welding tend to be compact and therefore light in weight and low in cost. This advantage is even more pronounced in the automotive industry. Because of their light weight, they often have the advantage of low fuel consumption. For a long time, EMAG has always followed this goal by providing users with all the processing technology and processes needed to process circular and “non-circular” parts and assemblies. After many workpieces have been machined, they must be joined and laser welded to form an assembly. Since 2003, EMAG Group and EMAG Laser Technology have cooperated to provide users with a complete production plan from cutting to laser welding for the production of assemblies that can be installed directly.

Die ELC 250 DUO

The ELC 250 DUO is a very compact laser processing device. Processing stations, lasers, laser cooling units, electrical cabinets and peripherals are all mounted on a load-bearing rack. The advantages of this compact structure are: high accuracy, good long-term stability, short installation time, and easy displacement of the laser welding device, so it can be quickly adjusted according to changes in production conditions. The ELC series DUO equipment is a twin-spindle device. This double-station machine can finish loading and unloading at the same time as the main machining. The device integrates a beam splitter for laser switching. This design optimizes the availability of the laser and improves the efficiency of the laser device.

The ELC-type laser equipment is equipped with a diffusion-cooled CO2-layered laser (DC Diffusion Cooled Baureihe) from ROFIN SINAR. The advantages of the DC Series are its excellent focusing performance and its extremely compact structure. The company's costs, especially energy consumption, laser consumption and maintenance costs are very low. Due to the excellent focusing performance of the laser (k value > 0.9, ie close to its physical limit K = 1), the geometry of the weld can be completely matched to the requirements of the workpiece. Welds can be very fine, deep and thick, and produce very little heat. The laser system cooled by the diffusion method has low operating cost and extremely low laser consumption. It uses a bottle of premixed laser gas to provide air.

The interior of the laser welding equipment has a spacious maintenance door, so the replacement or maintenance is very convenient and time-saving. In order to increase production efficiency and reduce replacement time, a new workpiece transfer method was adopted. The EMAG ELC 250 DUO laser machine has 12 NC axes, greatly improving the flexibility of the workpiece conveying channel, and greatly reducing the time required for switching in small batches. The "brains" of ELC equipment is the SINUMERIK 840D control system. In this control system, a number of Emac Laser Technology's practical auxiliary software are also integrated.

The advantages of laser welding are:

High power density, high process speed, low heat production, small part deformation, reliable process

Improve efficiency through dual-spindle design

Laser welding crown gear on differential case

In the actual production, laser welding equipment has put forward high requirements for high efficiency, high quality, and high operating rate. Otherwise, the laser welding will often cause bottlenecks in production. Therefore, the welding station is configured with two spindles: when one spindle is welding, the other spindle blanks the welded assembly and feeds the next welding and clamps the workpiece. The welding head switches between the two stations, which has the advantage of optimal laser utilization and high equipment efficiency.

The ELC 250 DUO is the best device for machining gearbox shafts

Laser welded differential case assembly. The crown gear and the differential housing are connected by laser welding. Therefore, it is no longer necessary to screw the crown gear into the differential case.

Gearbox manufacturing is one of the more and more areas of laser welding applications. Many parts, especially the differential case and drive shaft used in car transmissions, are often joined together and welded after the individual parts have been produced. The gearbox manufactured by this method has a compact structure, stable operation, and high power density. Compared with the method of assembling the differential case with the crown gear by the bolt fastening method, the laser welding method has gained more and more people's favor.

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