The car makes medium remote control solder technology

3 S. Stipulated laser solders on user part drawing, because this spare parts has been in Germany to produce with this kind of means, and Mexican factory also uses same part to assemble a car. To decide most agree with the laser beam welding of this utility receives technology, autotek uses Nd:Y to industrial robotAG laser and remote control solder CO2 laser undertook evaluating. As above, this spare parts uses Nd:Y in GermanyAG laser and industrial robot are produced. Autotek solders for these two kinds means made plan respectively, and to a few potential " compositive system supplier " inquiry and obtain investment cost. The verdict that uses in the light of this generalizes as follows: ◆ the investment charge of two systems is roughly same, workstation of a RWS and 2 Nd:YThe cost of AG laser matchs. Have Nd:YAG system solders a spare parts needs 24 seconds. Cycle time analysis shows, RWS can be inside 26 seconds solder 2 (be afore-mentioned results almost double) . Accordingly, between actual production, RWS can achieve every 15.

3 seconds full load productivity. The maintenance of ◆ RWS system cost is low much. Rofin " attrib wattle type " CO2 laser does not need to change any optical parts of an apparatus, simply every 8 months replacing to mix gas cylinder beforehand. And Nd:YAG laser need changes often pump riverside lamp, bad news report is bigger, and often must change the over cap of focusing lens. ◆ RWS easily the welding line figure with programmed control different implementation and the function that place solder, this one character is according to spare parts structure " custom-built " welding line mode, improve overall solder intensity and spare parts stiffness provided bigger flexibility. ◆ RWS is offerred power mixes taller laser to solder from the position is fast (50ms) " jump " solder to another positional ability. This accelerated manufacturing cycle greatly, to will use this system to solder henceforth other spare parts provided flexibility. According to this one analysis, autotek concludes, the utility that hits pole with respect to side of solder relieve a garrison, RWS is the solution that has cost advantage and taller flexibility. Remote control laser beam welding receives the century on the principle 90 time later period, high-power (laser of the smallest 3kW) CO2 can have offerred quality of very high beam of light. If the graph is shown 2 times, standard RWS includes high-power (can amount to 6 KW) CO2 laser and " remote control " long focal distance (normally 1000mm-1600mm) scans system. By the motion of computer drive the system can resemble a robot or CNC controller implements process designing method in that way, the laser of component of gold of the Ban that finish solders. Motion of scanning of beam of light relies on high speed electric machinery of galvanometric " of linear electric machinery or " , these but by manufacturer set. This makes beam of light can solder from positional whisk solders to another the position, what need time little at 50ms. The scanner still offers custom-built form but appearance of program welding line (the mode such as form of sutural form, annular, scale) , make the user can use the most appropriate solder path rough sketch to special weld. Soldering is remote control laser beam welding under diagnostic contrast receive the comparative essentials with conventional technology, cover an area of the advantage of area respect with explaining RWS craft is mixed in cycle time further. Resistance welding: Resistance welding or spot welding have the following and typical parameter: Weld time + the time ≈ 3~4 S of robot shift welding torch; Can solder 2~3 layer, 2-4mm of ≈ of total ply of standard mother capable person; Can solder galvanization and naked armor plate; When soldering, welding torch rises " pincers " action, help mother capable person together. Arc welding: Arc welding (GMAW) have following typical parameter commonly: Solder speed ≈ 1m/min; Use orgnaization sending silk to solder diverse welding line (welding line of fillet weld, butt joint) , but solder 2; Ply of mother capable person is 1~3 Mm normally, total ply 2~6mm; Can solder galvanization and naked armor plate; The assembly that diameter of concessional 1/2 welding wire controls clearance. Laser solders: Machines and tools of laser beam welding of remote control CO2 is like next typical parameter: Solder speed ≈ 3~6 M/min; Weld time is made an appointment with 0.

2~0.

3 S, assume 15mm of ≈ of welding line of a spot welding; Can solder 2~3 layer, 2-4mm of ≈ of total ply of standard mother capable person; Can solder galvanization or naked armor plate, but the volatile that must solve zinc arranges an issue; Requirement solder contact is the biggest assemble clearance to be in 0.

1~0.

2mm left and right sides. Cycle time is comparative: As above, laser beam welding fast fast at conventional technology, anyhow, the marked gain of cycle time still comes from be in at stimulating beam of light between welding line " sudden shift " , change quickly namely solder the position. The robot needs normally 0.

5~3s shift solders to the next the position, and remote control welder is less than 50ms. If mix weld time " sudden shift " time addition, the cycle time that can conclude remote control solders compares robot Nd:YAG is controlled 2 times more quickly, faster than resistance welding or arc welding 6~10 times. Cover an area of an area to contrast: Remote control solders the law solders than other law fast 2~6 times, because this is general,need covers an area of an area lesserly. The fact is really such, because solder the amount of power source and solder stage and the amount of transmission equipment decreased apparently. Solder with other methodological photograph is compared, RWS device may occupy the space of 25~50% only, because of utility different. Flexibility is comparative: Welding torch and spare parts do not have actual contact, because this can be adjusted at any time,solder the stage makes get used to other part, simply changes tool and call different program. Such making that its were had one-stop processing a series of by low to in the ability of assembly parts of gold of batch punch Ban. If the product includes a lot of need turnover,small area works the spare parts of the area, the thing that changes need intelligence sheds a solution. Systematic layout and demonstrative Magna-Autotek determination make he are become " compositive supplier " , so that control tool better,be designed and understand whole technology better. Systematic layout and tool are designed only then in March 2003. To December 2003, the system is assembled end and solder first spare parts. Laser, scanner and condenser install the coping in interlining entirely, in order to save a space. In scanner box below it is workbench of type of a circumgyrate, workbench contains two clamping apparatus, because this is OK,solder in a clamping apparatus spare parts while another clamping apparatus undertakes going up expecting. Stair is the channel that undertakes to interlining daily system is safeguarded. Whole laser unit must be located on special base, be not worth the vibration of 25 meters far punch workshop in order to absorb distance laser unit. To avoid to produce big accident, undertaking before installation vibration is measured is indispensable. Ground vibration must be less than the limit that laser manufacturer sets. And, must consider to install exhaust system, because soot can absorb laser. Its design effective system the thought is duplex operation of type of a circumgyrate the hand moves fluctuation makings workbench, outfit be versed in at two clamping apparatus use at left door assembly parts solder, outfit be versed in at another two clamping apparatus use at assembly parts of right side door solder. Operator comes down the package discharge that has soldered, put them into the case, lade next a group of new stamping workpiece, by " begin circularly " key. Then, workbench rotates, start solder program, the process repeats undertake. To protect an eye, have one side half wall rotates along with rotary table, to solder the process provides a not pervious to light sealed environment. For the safety of plant personnel, the system undertakes closing with small plate entirely, form " I class " safety solders system. Tool and plasma restrain: Although remote control laser beam welding receives law rate fast and save a space greatly, but there is a few to must give really in face of recipe of tool and spare parts outfit the difficult problem of the consideration. Laser light beam does not have active force, unlike falls in spot welding means, electrode outfit is on the pincers of welding torch or drive of hydraulic pressure oil cylinder. As above, arc welding is received use orgnaization sending silk, and considered welding line clearance. Accordingly, to locate and secure the position that wait for solder, laser beam welding receives need tool clamping apparatus. In addition, when laser beam welding receives galvanization data, need tries to discharge zincic volatile. Otherwise, zinc is soldering the process can volatilize, make welding line produces additional hole and stoma. If solder galvanization material, tool must be united in wedlock with photograph of clamping apparatus of appropriative spare parts, provide the means of volatile eduction jointly. Without giving thought to metallic film how (galvanization or without film) , CO2 solders normally need is restrained and / or break up the plasma that receives process generation in laser beam welding, because plasma interference stimulates beam of light, the likelihood is caused the process is not stabilized or cannot solder complete. "Plasma restrains gas " or " protective gas " can be helium, nitrogen, air or some kind of gas mixture, decide because of specific utility and laser power volume. For success application remote control solders technology, the position of aeriform nozzle and opening order also is a main factor that deserves a consideration. Autotek proper motion is designed and made tool fixture, the suitable costume clip that satisfied pair of spare partses and fixed position protect the demand of aeriform nozzle. The first archetypal tool was finished in January 2003, the Promatek R&D center that installing Magna of the rude Lan Pudui that save cloth undertakes trying solder. Regard its as the one share that ceaseless process improves, autotek is undertaking the 3rd times improvement to spare parts clamping apparatus now. Hardware design: The stamping workpiece supplier that uses laser beam welding to receive a technology had solved volatile to arrange an issue, the method is in embossing of the area that wait for solder an indentation or round nest, this feature can accomplish punch model to go up directly, also can add later in punch working procedure. Final result is to form 0.

1~0.

The clearance of 2 Mm, the volatilization that is zinc put apart a passageway. Differ with spot welding, laser welding line is very narrow, and simply undertakes bosseyed solder. The scanning lens of remote control welder can make different welding line figure or type below programme controll. In addition, the part that laser beam welding receives is better than tigidity of spot welding spare parts, bend not easily. The design in the spare parts must remember these concepts well in the process, the advantage that so that make full use of,laser solders. Welding line width is smaller, reduce spare parts weight likely. Say to fetch of laser beam welding, the clearance opening that a lot of spot welding application need is needless. Autotek prevents side to bump into lever to solder in the light of this the project had a consideration to afore-mentioned problems. From the graph 5 visible, the position that wait for solder is strong have roundlet hole, the volatilization that is zinc is offerred convenient. There are 12 welding lines on the spare parts, fashion the package of strong tigidity. Remote control welder is installed and compare new job of the spare parts, although made clamping apparatus use standard component, but in clamping apparatus of special spare parts, protection gas is discharged and need to expend a lot of time and energy on the development of punch craft. When the new use that the consideration has remote control solders, must put apart time undertakes these craft study. For example, although serve as air,protect gas at present, but Autotek is considering other gas to improve productivity. Epilogue Autotek is North America one of first manufacturers that install remote control laser beam welding to receive facility. Such system has following advantages: Compare with traditional method photograph, productivity can raise 10 times at most; Systematic layout can compare small 3~4 of traditional position area times; To production the spot provides bigger flexibility; The spare parts can be used at getting used to the need that laser beam welding accepts by the design, solder the spare parts that come out is lighter, stronger. Autotek took likely step in order to implement this one technology: In initiative executive phase, evaluate all sorts of options carefully, the choice has the kind of cost effectiveness most. Handle every detail of the process seriously, ensure successful outcome; The laser solderability that spare parts of examine and verify designs, include those who conduce to zinc volatilizing to add " dimple " ; Design and make the spare parts fixture that suits to be received at remote control laser beam welding; The time with enough put apart has the development before put into production; Decide at an early date and groom the member that be carried out to the system and operate responsible small composition. Today, the installation amount of the RWS in be being produced actually is more and more. Although laser and resistance welding or arc welding (it is costlier that GMAW) photograph is compared solder the sources of energy, but systematic totle drilling cost is about the same still, and RWS technology has a lot of advantages. Of course, this technology is not agree with every spare parts, but the research of this exemple showed it is a kind of success and good choice, can solder with what will replace a tradition technology. Receive a standard to judge remote control laser beam welding applicable, answer to design the first try phase with manufacturing cycle to undertake proper analysis in the spare parts. In addition, car architect should consider hardware design and constructional solution, it is easier to make production becomes, faster, cheaper. RWS is solder wonderfully solution, should bring into this one design so among the process. CNC Milling