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激光焊接设备是实现高效、优化和高效的板材加工的先决条件

 

 

 

激光焊接设备

weil technology 的激光焊接设备基于标准化的平台和模块,可针对组件、客户和项目特定的生产系统进行配置。激光焊接工艺对比其他焊接方法的优点主要在于焊接速度快 10 倍。结果是非常坚固且耐用的焊接连接件、在部件中产生更少的热量输入,以及几乎对工件不造成扭曲。

激光焊接设备的基架由坚固的抗扭曲焊接结构组成,采用面板结构,与热成型钢结构型材相结合。每一台激光焊接设备的核心件包括焊接工位、坚固的钢质焊接结构(经过无应力的退火处理),在其上布置有用于激光焊接光学系统的轴。所有激光焊接系统都通过可通行的保护间完全封闭,以防止激光辐射逸出。

激光焊接设备为设备配置了所有激光技术(光纤、光盘、CO2、激光混合),以便以最佳的激光束质量产生完美的焊接效果。所有激光焊接设备都优化配置有用于特定部件的夹紧技术,从而可以进行灵活的生产,并通过更换模具快速、安全地进行改装。

可选择为激光焊接流程配置流程数据监控功能,可识别和避免出现焊接故障。可集成其他数据监控流程。冷却和焊接烟雾抽吸是交付范围的固定组成部分。

weil technology 的激光焊接设备分为短管生产设备激光焊接模块激光焊接单元

激光焊接设备:短管生产设备

用于高效生产短管和用于高品质特殊应用的激光焊接系统。用于生产长度最大为 3.0 m、壁厚最大为 3 mm、直径范围为 30 至 1200 mm 的管材的单工位和多工位系统,管材生产线配置倒圆弯折工位,用于大批量生产的连续管材焊接机和深入加工装置(例如管端成型、管材切割机、校准和扩展设备)。

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压力)容器和水罐的激光焊接

weil technology 为半自动和全自动生产容器提供完整的产品组合,包括从卷材到完整的激光焊接产品的连续工艺链。这些生产线的产能可达每个班次 1000 至 1600 个零件。目前,我们可生产管材直径为 120 至 600 mm、管材长度最大为 2000 mm、板材厚度为 2.5 mm 的容器。

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柔性激光解决方案:模块化和柔性激光焊接与激光切割单元

多轴激光焊接单元最多配置 5 个轴,用于在一次夹紧的同时加工复杂的部件;可满足激光要求的多工位转台设备;用于简便、清楚明了地进行安装/焊接和检查流程的模块化生产线,用于生产复杂的组件;用于在一次夹紧期间进行切割和焊接的激光单元,配备灵活的模具方案和材料流方案。

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Further interesting aspects: welding and cutting

Value-added coalitions in the interest of our customers

When selecting laser components, we consider not only customer requests for specific installations, but also the technical requirements applicable in laser cutting and welding tasks, to help ensure an optimal process.

If order processing has already been carried out in our TechCenter feasibility or process stability studies, the question of which laser sources to use has already been answered. We generally work with global laser system manufacturers such as Trumpf, Rofin-Sinar, IPG and Laserline, as well as with OTC Daihen and Fronius in the arc welding area.

TruDisk is the most frequently integrated laser by weil technology

The most frequently used type of high power solid-state laser used is the TruDisk by Trumpf Laser GmbH, which can be used in both laser cutting and laser welding processes. This unit is an optimal choice for meeting our requirements for precision and reproducibility in cutting and welding results. The advantage of using the laser here is in creating smooth and burr-free edges that require no reworking, and in very small heat affected zones (low warpage).

In some applications, this type of laser was useful as a beam source in combination with scanner optics, in which the movable mirror guides the focusing optics of the laser beam. The fast adjusting movements by the mirror provide highly dynamic and precise welding results.

Spatter-free laser welding

An increasing number of applications require not only almost spatter-free laser welding, but also outstanding weld seam quality with no spatter. The “BrightLine Weld” option from the TruDisk laser gets us one step closer to this goal. Primarily developed to weld copper and reduce weld spatter, “BrightLine Weld” offers the ability to create high-quality weld seams without end craters or seam collapse. The system prevents spatter first by welding with a high feed rate, and second with a “2in1 fibre” patented by Trumpf – two fibre optics in a single fibre – where two laser beams with different power distribution act on the weld seam. The result is reduced energy input and no component distortion, faster feed speeds / welding speeds, 40% lower energy consumption and lower levels of contamination on components and protective equipment.

High power diode laser by Laserline

Diode lasers by Laserline (LDF, LDM) are also frequently used. In tasks with lower performance requirements, such as with sheet metal up to 0.8 mm thick, or lower requirements for the characteristics and appearance of the weld seam, the ease of integrating this option into welding machines and lower investment and operating cost make it possible to substitute diode lasers in laser applications.

High power CW ytterbium fibre laser systems by IPG

weil technology uses laser sources from IPG primarily for applications in laser cutting systems.

Arc welding vs LASER

Arc welding or electrode welding is a manual process. The electrode used melts, evaporating inert gases and forming slag that protects the weld seam from external influences.

Inert gases are also used in inert gas welding; these flow around the electrode and melt and replace atmospheric oxygen. Inert gas welding can be fully automated. If specifically requested by a customer, for instance, we can integrate a tungsten inert gas welding source (WIG) into a raw material production system. In this process, a non-melting tungsten electrode is used to achieve a high-quality seam with slower welding speeds than in gas metal arc welding (manual metal arc welding MMAW). Metal inert gas welding (MIG) also uses inert gases – gases that do not chemically react with the melt – and is best suited for non-ferrous metals and high alloy steels. If reactive gases are used that change the composition of the melt – such as in un- or non-alloyed steels – the process is called metal active gas welding (MAG).

Slags and an obvious weld bead are the external signs of MAG welding, while a lack of through-weld, joint defects or the formation of corrosive areas are underlying disadvantages. Another problem is obvious weld spatter, which requires manual reworking to remove and makes the overall process more expensive.

10x faster speeds with lasers

Another advantage of the laser are the 10x higher speeds that can be achieved over MIG or MAG welding. No additional materials are required, but they can be added if necessary. Other advantages of laser welding:

  • Laser welding results in low warpage; faster process speeds allow for more beneficial welding strategies;
  • A laser weld seam requires no seam preparation, since the single layer welding penetration depth (> 10 mm) eliminates the need for expensive weld preparations;
  • Laser welded seams do not have to be reworked, since the width-depth ratio of 1:5 creates an aesthetically pleasing seam appearance that normally does not require reworking.
  • Laser welding is not only technically impressive, but offers major economic advantages for users when applied correctly.

Automated welding – excellent reproducibility with high-quality clamping tools

The laser beam, just a few µ in width, requires precise guidance to hit the welded sheet metal edges, melt and bond them. Automated clamping technology is required to clamp the weld seam perfectly and completely over its entire length, holding it in place for the entirety of the welding process.

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Flexible Laser Solutions

细胞激光

应用于切割和焊接的激光切割/焊接机床,模块化及柔性激光加工单元;制造工艺的柔性激光解决方案

短管生产系统

用于生产短管和用于特殊应用的焊接技术