Remote laser beam welding and cutting can be applied to a wide range of applications within the manufacturing technology domain. With high process rates, consistent high quality welding seams and cutting edges at various contours these technologies offer an increased flexibility to process a wide variety of work pieces. To take advantage of the process the laser beam must be positioned precisely on the work piece. Programming a system of an industrial robot combined with a laser beam deflecting scanner manually is a very time consuming job. Programming any ''on the fly'' movements, a synchronously movement of the scanner and the robot, is even more difficult. This paper describes challenges and a concept for the automated programming of the two devices to apply the advantages of remote laser beam welding and cutting. Remote laser beam welding and cuttingRemote laser beam welding (RLW) and cutting (RLC) (see Fig. 1) facilitated by their contactless process and their high operational speed, are versatile technologies with promising futures [1-3]. The remote technology allows the user to program any desired welding seams or cutting edges without running the risk of collisions between the laser forming optics and the work piece or its clamping device [4]. The versatility of remote systems is increased by combining both processes in one optics. Since no specialized hardware is needed for either process, the changeover between RLW and RLC is controlled by a software and can be integrated into an automated path planning.Compared to resistance spot welding a process presently used mainly in the production of automobiles, the application of RLW can reduce the cycle time by up to 80% [5]. A comparison of RLC to a conventional laser cutting linear drive machine also shows a great potential for reducing production times [6,7]. However, there is still a large amount of research to be done for both techniques on the programming of the used devices. At the moment, the application of robotic based RLW with scanners is profitable only when dealing with lot sizes of over 100,000 pieces per year or those that require numerous welding seams per work piece [3,5].Research work on RLW and RLC can be broken down into two fields [8]: First, reviewing and analyzing the process in order to gain a better understanding of the handling of the work piece is essential. Finding the optimal parameters for the laser power, speed of operation and valid inclination angles is one goal in the field of process studies [2,9]. Secondly, the focus of the laser must be positioned precisely on the work piece [4,10]. This paper deals with an algorithm for the automatic path planning of a robot and scanner based positioning of the laser beam. The introduced method offers more flexibility in specifying information for the welding seams and cutting edges when compared to programming the robot motion manually.
Remote Ablation Cutting (RAC) is a most promising process for cutting thin metal sheets in the automotive, medical and consumer industry. Characteristically for the RAC are high cutting velocities for metal foils as well as material processing of box structures without spatter contamination at the inner surface. Furthermore, the system technology for RAC can also be used for other processes, like welding and marking. Thereby, the flexibility of a production unit is increased, compared to a conventional cutting system. Despite several advantages, the RAC is not yet state of the art in industrial production. Reasons for that are lacking knowledge in the area of process itself and in possible application areas.In this paper a conceptual model of the ablation and the ejection mechanism is presented. It consists of the laser beam absorption within the processing zone, the melt ejection from the kerf and the resulting spatter formation above the part surface. Besides the model, the process boundaries and limitations are identified using empirical data.Addressing possible applications, the following samples of different industrial areas are introduced to show the potential of the process: Cutting of heat exchanger plates, cylinder head seals, and cathode/anode material for Li-Ion-Batteries. Furthermore, a concept and first results of the combined processing of remote cutting and welding with one laser and one scanner optics are presented.
-Remote laser beam welding (R laser beam cutting (RLC) are technologies that a automated applications in industrial faciliti contactless mode of action. The main adv processes are the high operation speed, good pr a tailored contour of the welding seams and cut optimal use of these processes the laser beam accurately over the work piece. A common tec of such processes is the combination of a laser unit, a laser scanner and an industrial ro represents a programming challenge, as the freedom of the robot plus the two degrees of fre scanner lead to a kinematic redundant syste advantages of this combination, the large robo the fast and precise motion of the laser scanne attractive technology for improvement of wel processes. An automated programming system setup is presented in this paper.
Kurzfassung Die Harmonisierung und Nivellierung von Produktionsaufträgen verringert negative Folgen von Nachfrageschwankungen in Supply Chains von produzierenden Unternehmen. Die erfolgreiche Einführung einer Produktionsnivellierung hat neben einer gesteigerten Synchronisation mit externen Partnerunternehmen ebenfalls starke Vorteile für die internen Distributions- und Produktionsstrukturen. Der vorliegende Beitrag erläutert die simulationsgestützte Bewertung von Nivellierungskonzepten anhand von drei Dispositionsstufen eines Produktionsstandortes variantenreicher Serienprodukte. Der Vorgehensweise zur Klassifizierung und Systematisierung der Varianten zu Produktfamilien und der Ableitung geeigneter Nivellierungsfenster folgt die Aufstellung der wichtigsten Parameter für die Planung einer Produktionsnivellierung bei hoher Variantenzahl.
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