uofv laser based manufacturing in the automotive industry presentations... · laser based...

University of Virginia - November 2010Lasers in the Automotive Industry 1

Laser Based Manufacturing in the Automotive Industry

TRUMPF, Inc.

David HavrillaManager – Product & Applications


Agenda

Introduction

Trends in Laser Welding> Remote welding> Conventional laser welding> Brazing

Trends in Laser Cutting> Remote cutting> High speed cutting

Conclusion


Powertrain

Motor

Torque ConvertersClutches

Gearbox

Driveshafts

Differentials

Roof

Brazing

Trunk lidB-Pillar

Tunnel

Hotforming

A-Pillar

Side memberDoor enforcementsBumper

Roof rail

Cross member

Side Panel

Doors

Rear CenterComponent

Seat Rests, Tracks, Recliners

Remote

Side member

IP Beam

Bumper

Battery

Laser applications - Automotive Industry


Exhaust systems

Chassis/BIW

Suspension

ElectronicInteriorPassenger-safety

Engine

Powertrain

Components

Laser applications - Automotive Industry


Manufacturing technology> application incubators> decreased investment cost> green synergy> throughput requirements

End product requirements> miniaturization> performance> weight reduction> cost reduction

Trend drivers


Solid stateDiode pumpedExcellent beam qualityCompactHigh WPEFiber deliveredModular design> 1,000 sold

Disk Laser technology

TLS Disk - Cavity


Principles of Programmable Focusing Optics

2D Scanner PFO 20PFO 33

3D ScannerPFO 3D


appr

oach

Wel

ding

1

Posi

tioni

ng 1

Wel

ding

2

Posi

tiotn

ing

2

Wel

ding

3

Posi

tioni

ng 3

Wel

ding

4

Posi

tioni

ng 4

Wel

ding

5

Posi

tioni

ng 5

Wel

ding

6

Posi

tioni

ng 6

Wel

ding

7

Posi

tioni

ng 7

Wel

ding

8

Hom

e

Conventional Laser Welding

Process Start Process End

Appr

oach

Wel

ding

1

Wel

ding

2

Wel

ding

3

Wel

ding

4

Wel

ding

5

Wel

ding

6

Wel

ding

7

Wel

ding

8

Hom

eElimination of non-productive travelling timesMaximization of beam-on share

Laser Scanner Welding

Process Start Process End

unproductivetravelling times

Remote welding – increased productivity


Customized weld patterns allow for optimum strength of the joints and increased design flexibility due to:

virtually any weld seam shapesvirtually any orientation of weld seamsuser defined distribution of weld seamsoptimum flow of forces

➩ reduced flange width

➩ material, weight andcost savings

Remote welding – increased flexibility


Picture: Daimler

Picture: Daimler

Trunk Lid / Rear Panels Doors / Hang-on Parts Side Walls

B pillar

Remote welding in body-in-white


Recliners Seat Frames

Seat PanelsSeat Tracks

Scanner welding: Seating


Instrument Panel Carrier for automotive dashboards

Scanner welding: IP beams


Laser remote weld - production

34 + shift code 1 robot, 1 scanner optic Welding time 13 s, ~9.5 s w/ 6 kW

Spot weld - production

34 + mech. shift code4 robots, 5 welding guns Welding time: 34.7s

Source: Volkswagen AG

Scanner welding: VW Passat hat rack


Problem: Vaporization of Zn in between the panels causesweld spatter on the surface:

Poor weld seam quality

technical „0-gap“

Possible solutions to manage the problem:

Spacers integrated in:fixturepart design

Adapted melt pool dynamics(twin-spot focus)Adapted coating (Zn-Mg)Gap created by dimples

0.2 mm gap

Lap welding of Zn coated panels


Constant dimple height (depending on zinc layer 0.1 - 0.2 mm (approximately)

Dimple height adjustable via laser parameter

Laser dimpling


Step 1: Laser Dimpling

Step 2:Placement ofupper sheet

Step 3:Laser Scanner Welding

BEO or

PFO

PFOFeed Feed

Laser dimpling process


5 laser dimples are covering the area of the later C-shaped weld seam

Spot pattern for laser dimpling


welded parts:

Automotive Doors: Mercedes-Benz C and E class

welding station:

Source: Daimler AG

Production at Mercedes-Benz


530 million remote welded seams by 2009 year end

Sedans and wagons welded on the same RobScan line

35% floor space reduction

40% cost reduction

Excellent part dimensional accuracy

Higher vehicle structural stiffness at lower weight

Remote welding success Mercedes-Benz


Maximum viewing angle, window & door opening as customer benefit.

Consequence:Welding flange (< 6 mm).No conventional spot welding technology possible.

AUDI Q5 requirements to the door concept

Scanner welding: Audi Q5 door


Solution:Remote laser welding with PFO33

45 laser stitches (25 – 40mm each)

Cycle time < 30 sec

2220

1917

151311 2118

1614

12

10

9

87

6

5

43 2 1

31

30

28

26

24

32

29

27

25

23

40

41

42

43

44

45

3938 37 36 35

3433



Remote Welding of doors in high-volume productionAudi A4 / Q5



Conventional Laser weld with a Trumpf TruDisk 4002 and welding head with filler wire.

Conventional welding: BMW aluminum door


7 Series Sedan

• 15,4 meters of laser seam

7 Series Sedan Long

• 16,2 meters of laser seam



Laser welding of Aluminum doors BMW 7series sedan in production



Thyssen

Weight reductionLess materialLess transportation weight

Higher stabilityHigher dynamic strengthHigher crash performance

Reduced quantity of partsLess tooling costLess forming costLess logistics cost

Tailor welded blanks


Tailor welded blanks


Longitudinal Transverse

Mat

eria

lW

all t

hick

ness

Tubes & Tailor welded tubes


MotorGearbox Driveshafts

Differentials

Brakes / Hubs

Wheel

Torque Converters

Clutches

Damper Parts

Powertrain


Step 1Overlap JointResistance weldingSealer15mm molding

Step 2Overlap Joint Laser stitch weldingSealer8mm molding

Step 3Edge Fillet Laser weldingNo Sealer8mm molding

Step 4Fillet JointLaser brazingNo SealerNo roof ditchNo molding

Laser brazing – Roof Joint

y- / z-Compensation


American License Plate

European License Plate

Global Products customized to local markets with the help of laser technology.

Laser brazing – deck lid


Melt ejection by melt pressure downwards

Remote cutting on the fly with PFO (no cutting nozzle!)

Good (burr free) cut quality, but oxidation layer

Up to 4 mm sheet thickness

Cutting speed < welding speed (approx. 50%)

One tool for remote welding & cutting

t = 1mm;, v = 8m/min; P = 6 kW t = 3mm; v = 3.5 m/min; P = 6 kWt = 2x 1 mm; v = ca. 3 m/min;

P = 4 kW; kerf welded together

pv

melt

Top side

Bottom side

Melt pressure cutting


Melt pressure cutting


Cutting with disk laser

Material: 1.4301Power: 1000 WFocus: 100 µm Thickness: 0.8 mm Speed: 15 m/minGas: N2Pressure: 12 bar


TruF

low

(CO

2)Tr

uDis

k (F

KL)

TruLaser Cell 7000 series


Maximum production speed for mild steel and stainless steel

0

5

10

15

20

25

30

35

1,0 mm 1,5 mm 1,8 mm 2,0 mm

TruDisk 2001

TruFlow 5000

TruDisk 3001

Production speed* *

*3D processing speed depends on part geometry

Faster cutting with SSL in thin sheets


Cutting of hot stamped material


Innovative technologies can be trend drivers

The beam quality & power of TRUMPF’s disk laser has enabled several recent applications employed by automotive:

Remote weldingRemote welding of zinc coated steels w/ dimplingHigh speed robotic cuttingRemote cuttingHigh speed 3D cutting

The automotive industry has a incorporated laser processing in virtually every sub-system of the automobile

Ongoing laser innovations will continue to enable new trends in materials processing and will continue to make laser implementation more and more affordable

Conclusion

University of Virginia - November 2010Lasers in the Automotive Industry

Thank you

TRUMPF Laser Technology CenterPlymouth, MI(734) 454-7200

uofv laser based manufacturing in the automotive industry presentations... · laser based...

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