Laser scanning welding technology applied to Audi A4 doors
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In the development of robot-controlled laser scanning and welding technology, the biggest challenge is to develop a laser source that can excite high-quality laser beams. In the traditional laser welding application, the industrial applicability of a lamp pump system with a beam quality of 25 mm has been proven thousands of times. However, for laser scanning welding, a higher beam quality is required because the working space of the optical scanning system and the possible working area depend on the beam quality. Simply improving the beam quality by changing the geometry of the laser bar is no longer sufficient. Only newer, revolutionary lasers can meet the need to improve beam quality. TRUMPF has developed disc lasers for industrial users and has been widely used worldwide (as shown in Figure 1). It has a high power laser with a beam quality of 8mm.mrad and a maximum power of 8kw. Disc lasers are used in all laser applications, from cutting, conventional soldering to laser scanning soldering.
In addition, TRUMPF has developed a dedicated scanning weld head for industrial applications of high power lasers. At present, only the robot guidance solution developed by the company has passed the rigorous certification test of the German automotive industry and has been applied to its series production (see Figure 2). Recently, DaimlerChrysler's new body manufacturing has adopted this process.
Compared with the traditional welding process, the biggest advantage of laser scanning welding is that the production efficiency is greatly improved. In the past, the time spent positioning the robot was greatly reduced due to the rapid mirroring movement of the scanning head, so that the entire processing time was greatly shortened. Conventional spot welding has a welding speed of 0.5 solder joints per second, while laser scanning soldering typically can complete 3 to 4 solder joints per second. Thereby more efficient use of the laser source, which in turn can greatly improve economic efficiency. In addition, a highly efficient disc laser system ensures low long-term use of the laser source. Compared to lamp-pumped laser systems, laser-scanning systems save 25% in electricity costs and reduce user infrastructure requirements (site area and cooling equipment).
Volkswagen and Audi's R&D engineers have developed the advantages of the laser scanning and welding process, and Audi has successfully solved the challenges of fixtures and components. Now the quality of the parts produced by the laser scanning welding process is even better. At the same time, Audi's experts have developed laser-assisted pretreatment technology to ensure that the galvanized layer processing components also have a high welding quality. The laser source they used was a Nd:YAG pulsed laser manufactured by TRUMPF.