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Robot Laser Welding Cell is Flexible & Fast

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To address the needs of the white goods and automotive industries in particular, expert system builder Cyan Tec Systems of Loughborough has developed a standard multi-axis robotic laser welding cell incorporating a 6-axis robot combined with a 2-axis tilt-and-turn manipulator to give the ultimate flexibility with 8 programmable axes. Such a system can work on large components or assemblies and present them in such a way to reduce the complexity of the robot moves and compress the overall cycle time.

More and more welding tasks are becoming automated as the lack of availability of skilled and experienced manual welders, and the requirements to achieve stringent and repeatable quality and higher throughput, drive production away from conventional joining processes towards laser welding.  In addition to this, the current trend in reshoring production from abroad promotes a high degree of automation which minimises the impact of international differences in labour rates, and reduces the cost and uncertainty associated with long distance logistics via sea or air freight.

The Hyperion MAR30WF is a standard system built by Cyan Tec using a 6-axis robot carrying a compact laser welding head from a multi-kW fibre laser source. The tilt and turn manipulator has an integral indexing system allowing parts to be safely unloaded and re-loaded during the welding cycle by an operator outside the Class 1 safety enclosure. Welding by laser is a non-contact process, where the laser beam is typically some distance from the final focusing optic. For best results a pipe delivers Argon assist gas which prevents oxidisation, leaving a bright and oxide-free weld which is capable of coating or painting after welding without any need for post-weld cleaning.

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Image: Standard Multi-axis robot laser welding cell

A highly efficient laser welding cell can be modified to process new products by simply re-programming the software and re-tooling for new configurations. Using a dedicated cell with a standard design gives the benefit of reduced cost and lead time for the capital equipment, as custom machinery is limited to the final tooling and the welding path programme.

Laser welding has the benefits of low heat input and excellent repeatability.  The accuracy and consistency reduces the amount of material required in flanges and enables novel joint arrangements since only single-sided access is required (unlike resistance spot welding).

Modern robots are faster, with higher accuracy and repeatability than previous generations. Cyan Tec has experience of integrating robots and lasers from all the major suppliers and can offer expert advice on the most appropriate solution for laser processing, paint spraying, assembly, test as well as many other applications. Standard and bespoke systems are offered with a full service from design through manufacture, a large installed base worldwide is supported by a dedicated team of engineers.

Shaping The Future of UK Joining Technology

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Following the installation of Cyan Tec Systems’ laser processing system which includes the UK’s most powerful laser at the Manufacturing Technology Centre (MTC) in Coventry in 2014, the advanced laser welding and cutting robot cell is being used by industrial partners of the MTC to advance manufacturing processes and improve efficiency. Rolls Royce, a founding member of the MTC and major user of the laser system in Coventry, has completed a project to replace resistance welding with laser welding in the manufacture of titanium fairings for its advanced aircraft engines.

Working with laser welding experts at the MTC, Rolls Royce has successfully completed a programme to improve consistency, increase throughput and reduce manual input in the manufacturing process. The laser welding cell at the MTC is equipped with a range of welding and cutting head options and is capable of handling large and heavy parts with ease – the laser processing head being carried on a 6-axis robot, which is integrated with a multi-axis manipulator.

 

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Image: The laser processing cell supplied to the MTC by Tec Systems

Welding titanium by laser can achieve excellent results as long as the correct shielding with argon is provided. The MTC designed and manufactured assembly tooling with integral shield gas delivery. After qualifying the weld process, using fatigue test coupons, full scale laser welded parts were produced on the Cyan Tec robot cell.  These parts proved that laser welding produced less distortion than the existing resistance welded assembly.

Having extensive experience in the integration of lasers with robots and CNC machines for welding, cutting, marking and drilling, Cyan Tec is well-placed to provide turnkey laser systems for the development of new processes and the mass production of proven assemblies using automation, lasers and custom manipulation.

Cyan Tec has experience of integrating robots and lasers from all the major suppliers and can offer expert advice on the most appropriate solution for laser processing, paint spraying, assembly, test and other applications.  Standard and bespoke systems are offered with a full service from design through manufacture, a large installed base worldwide is supported by a dedicated team of engineers.