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  • FAULHABER Worldwide
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  • Industrial Tools & Equipment
  • Diode lasers

A strong partnership

Laser beams can melt and even vaporise metals highly efficiently and very precisely. For this reason, they are increasingly used as a tool for joining components, namely for welding and soldering e.g. in the automotive industry. Normally, laser devices – like conventional welding torches – have a single focal point or "spot". Laserline has now developed multispot optics for laser soldering and welding which also allow particularly difficult materials to be processed. Motors from FAULHABER help to ensure that the spot energy is distributed correctly.

Zinc protects steel against rust. Vehicle manufacturers therefore mainly use zinc-plated sheet metal for vehicle bodies. Previously, the protective metallic coating was applied by means of electroplating. However, hot-dip galvanisation is now becoming the method of choice. It provides even better corrosion protection. When such hot-dip galvanised metal sheets were first used in production, an unexpected problem arose during soldering.

Soldering or welding?

Compared to welding, soldering offers a series of advantages for series production in the automotive industry. In the case of welding, the metal sheets are heated to melting temperature along the welding seam itself and the two sheets are then directly joined together. This requires a high degree of precision and it is not possible to achieve visible seam quality. Welded seams are rough and the vaporisation of zinc makes them porous. With soldering, however, a seam made of a different material is inserted as a filler material between the metal sheets. This coppersilicon solder – liquefies during soldering and then solidifies again – not only joins the parts together, but also fills the gap between them. As a result, soldering permits a greater dimensional tolerance and requires less effort with regard to clamping the workpieces. Above all, soldering allows gap-free joints to be made in visible quality, which means that the soldered components can then be painted without first having to undergo further processing.
In the case of hot-dip galvanised metal sheets, however, the solder does not behave in the usual way. "On the surfaces next to the seam there was increased spatter from liquid solder. Microspatter in particular occurred which is hard to see initially, but then becomes clearly visible after painting", reports Dr. Axel Luft, Automotive Sales Manager at Laserline. "There was also a deterioration in the quality of the actual seam. It was rougher and often formed socalled wavelets, in the other words points at which the solder crosses the planned seam boundary."

Soldering solution for hot-dip galvanised metal sheets

It was obvious that these problems had something to do with the zinc layer on the steel sheet. As a result of the hot-dip galvanisation, this layer had become thicker and less regular. Furthermore, it exhibited a different reflection behaviour, which also had a negative effect on the soldering process. Thorge Hammer, who as an engineer in the technology planning and development department at Volkswagen in Wolfsburg is responsible for this soldering process, had an idea how to solve this problem: The zinc should be removed from the edges of the seam before soldering takes place. However, this would require the usual circular laser spot to be rectangular and would also have to have an opening through which the solder can be fed. The "front" corners of the spot would then be responsible for removing the zinc, while the larger part of the rectangle performs the actual soldering.
"From a technical viewpoint, this solution was not possible, but we were on the right track", recalls Dr. Markus Baumann, chief development engineer at Laserline. "Instead of forming a spot with a complex – and therefore optically very difficult – shape, we finally added two smaller spots to the main spot. During soldering, these smaller spots are always directed at the edges of the seam in front of the main spot which measures a few square millimetres." Their energy is enough to vaporise the zinc layer in this area, to start to melt the steel and to generate slight oxidation. This produces a so-called passive layer that prevents sloshing of the solder liquefied by the main spot.
As a result, the soldered parts do not require subsequent work to remove solder spatter before painting. There is another reason why the rectangular main spot proved to be a good solution: It distributes heat over the solder more evenly than its circular counterpart, which also contributes to a calmer solder bath. "With this technology, we were finally able to solve all of the problems that we encountered with hot-dip galvanised metal sheets." says a delighted Dr. Luft. "It is now used in series production at VW. And it allows us to achieve a soldering speed of up to 4.5 metres per minute. Other manufacturers will follow soon."

Beam splitting with optics module

An optics module is responsible for ensuring precise alignment of the spots. It contains various optical elements that selectively modify the laser beam. The collimation lens aligns the divergent laser beams leaving the fibre-optic cable, so that they run parallel to each other. A so-called homogenisation array generates a square-shaped main spot, while other optical elements split the beam and generate additional spots. In the case of soldering, two leading spots are generated to the front and side of the main spot. To obtain the desired clean seam at the end of the process, the power distribution between the main and leading spots as well as between the leading spots must be precisely set. How the laser power is distributed to these spots depends on the position of the optical elements. By moving these elements in the x and y-axis, it is possible to achieve the precise distribution of laser power required for the task in question.
To deep-weld aluminium, for example, a small, intensive spot can be positioned inside the weaker large spot. To weld together metal sheets of different thicknesses, two spots can be adapted to the respective material. This can be done during the running process because the elements in the Laserline optics module are moved by motors.
The edge length of this square-shaped module is 12 centimetres, with a depth of 5 centimetres. The optical elements and a sophisticated mechanical system are housed in this small space. There isn't much room left for the motors. The primary requirement placed on the drives is therefore compactness.
"We opted for brushless DC-servomotors of the 1226 B FAULHABER series with 12 millimetre diameter, with lead screws bonded directly to the motor shaft and without shaft coupling", explains Dr. Baumann. "This provides us a very compact drive which nevertheless reliably delivers the required power and speed. Easy integration of the motor controller in the system was another important consideration." The Motion Controller from FAULHABER was housed outside of the module and communicates by means of an RS232 serial interface. If the Laserline customer so desires, the motor/controller combination can also be actuated via a CAN bus system without needing to make any changes to the mechanics or housing. The RS232 controller can easily be replaced with a version with CANopen interface.

Motor with position guarantee

The laser optics are mounted to a robot arm during soldering and welding; this robot arm moves the laser optics to the required position. The optics must withstand considerable dynamic loads which act on the motors and which can trigger unwanted changes in position. "This is no problem for the FAULHABER motor because it detects its current position using the integrated Hall sensor and if necessary readjusts – at the latest when the laser is positioned on the seam", emphasises Dr. Luft. "This gives us the certainty that any incorrect positioning is ruled out. Thanks to the high quality of the drives, we can rely on consistently reproducible results. This is crucial because our customers expect trouble-free operation over a period of at least seven years!"
For Dr. Baumann it was clear that he would find the right motor at FAULHABER – just as he did eight years ago when looking for the right motor for a new zoom optics system. Back then, stepper motors were generally used for this type of device. However, as the development engineer reports, these stepper motors had problems with the acceleration of masses in the robot arm: "The dynamic load can cause a stepper motor to miss out individual steps. To prevent this from happening, an encoder can additionally be used for position determination and readjustment. This is not only complicated but in this combination it is also expensive. When I was younger, I needed a compact motor for a model ship and I found it at FAULHABER. I remembered this when developing the zoom optics system, contacted FAULHABER and once again found the optimum drive. This has helped us create an extremely cost-effective solution that has since proven very successful." The new multispot module too carries out its work in series production flawlessly. Furthermore, this optical system has already gained widespread recognition among experts: The technical solution and the economic efficiency achieved in industrial applications over just a short period of time convinced the international jury of the "Innovation Award Laser Technology". This year, it awarded the developer team first prize.

Laser beams efficient and precise

Products

Brushless DC-Servomotors

Brushless DC-Servomotors Series 1226 ... B

Further Information

Laserline GmbH
www.laserline.com

Products

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About FAULHABER

  • Company Profile
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  • History
  • FAULHABER GROUP

Contact

  • Inquiry
  • FAULHABER Worldwide
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  • GTC
  • E-mail encryption
  • Imprint
  • Data privacy
  • GTC
  • Products
    • Online product catalogue
    • FAULHABER Drive selection
    • DC-Motors
      • FAULHABER S/G
        • 0615 ... S 1219 ... G 1516 ... S 1624 ... S 2230 ... S 2233 ... S
      • FAULHABER SR
        • 0816 ... SR 1016 ... SR 1024 ... SR 1224 ... SR 1319 ... SR 1331 ... SR 1516 ... SR 1524 ... SR 1717 ... SR 1724 ... SR 2224 ... SR 2232 ... SR
      • FAULHABER CXR
        • 1336 ... CXR 1727 ... CXR 1741 ... CXR 2237 ... CXR 2642 ... CXR 2657 ... CXR
      • FAULHABER CR
        • 2342 ... CR 2642 ... CR 2657 ... CR 2668 ... CR 3242 ... CR 3257 ... CR 3272 ... CR 3863 ... CR 3890 ... CR
      • FAULHABER SR-Flat
        • 1506 ... SR 1506 ... SR IE2-8 1512 ... SR 1512 ... SR IE2-8 2607 ... SR 2607 ... SR IE2-16 2619 ... SR 2619 ... SR ... IE2-16
      • Technical information
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        • 0308 ... B 0515 ... B
      • FAULHABER B
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        • 4490 ... B 4490 ... BS
      • FAULHABER BHx
        • 1645 ... BHS 1660 ... BHS 1660 ... BHT
      • FAULHABER BX4
        • 2232 ... BX4 2250 ... BX4 2250 ... BX4S 3242 ... BX4 3268 ... BX4
      • FAULHABER BP4
        • 2264 ... BP4 3274 ... BP4
      • FAULHABER B-Flat
        • 1509 ... B 1515 ... B 2610 ... B 2622 ... B
      • FAULHABER BXT
        • 2214 ... BXT H 2214 ... BXT R 3216 ... BXT H 3216 ... BXT R 4221 ... BXT H 4221 ... BXT R
      • Technical information
    • Motors with integrated Electronics
      • FAULHABER BRC
        • 1525 ... BRC 1935 ... BRC 3153 ... BRC
      • FAULHABER BX4 SC
        • 2232 ... BX4 SC 2250 ... BX4 S SC 2250 ... BX4 SC 3242 ... BX4 SC 3242 ... BX4 SCDC 3268 ... BX4 SC 3268 ... BX4 SCDC
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        • 2610 ... B SC 2622 ... B SC
      • FAULHABER B Cx
        • 3564 ... B Cx
      • FAULHABER BX4 CxD/Cx
        • 2232 ... BX4 CxD 2250 ... BX4 CxD 3242 ... BX4 Cx 3268 ... BX4 Cx
      • FAULHABER MCS
        • MCS 3242 ... BX4 ET MCS 3242 ... BX4 RS/CO MCS 3268 ... BX4 ET MCS 3268 ... BX4 RS/CO MCS 3274 ... BP4 ET MCS 3274 ... BP4 RS/CO
    • Linear DC-Servomotors
      • LM 0830 ... 01 LM 1247 ... 11 LM 1247 ... 12 LM 1483 ... 11 LM 1483 ... 12 LM 2070 ... 11 LM 2070 ... 12
    • Stepper Motors
      • AM0820 AM1020 AM1524 AM2224 AM2224R3 DM0620 DM1220 DM40100R DM52100N DM52100R DM52100S
    • Piezo motors
      • LL06... LR17... LT20... LTC300... LTC40 LTC450...
    • Precision Gearheads
      • Planetary Gearheads
        • 03A 06/1 06A 08/1 10/1 12/4 13A 14/1 15/10 15A 16/7 17/1
        • 20/1R 22/7 22E 22EKV 22F 22GPT 23/1 26/1 26/1R 26A 30/1 30/1 S
        • 32/3 32/3R 32A 32ALN 32GPT 38/1 38/1 S 38/2 38/2 S 38A 42GPT 44/1
      • Spur Gearheads and Spur Gearheads zero backlash
        • 08/2 08/3 12/3 12/5 15/5 15/5 S 15/8 16/5 16/5 S 16/8 16A 22/2
        • 22/5
    • Linear Components
      • Ball screws
        • BS22-1.5 BS32-2.0
      • Lead Screws and Options
        • M1,2 x 0,25 x L1 M1,6 x 0,35 x L1 M2 x 0,2 x L1 M3 x 0,5 x L1
    • Encoders
      • Incremental encoders
        • HEDL 5540 HEDS 5500 HEM3-256 W HXM3-64 IE2-1024 IE2-16 IE2-400 IE3-1024 IE3-1024 L IEF3-4096 IEF3-4096 L IEH2-4096
        • IEH3-4096 IEH3-4096L IEM3-1024 IER3-10000 IER3-10000 L IERS3-500 IERS3-500 L PA2-100 PA2-50 PE22-120
      • Absolute encoders
        • AES-4096 AES-4096 L AESM-4096
    • Drive Electronics
      • Speed Controller
        • SC 1801 F SC 1801 P SC 1801 S SC 2402 P SC 2804 S SC 5004 P SC 5008 S
      • Motion Controller
        • MC 5004 P MC 5004 P STO MC 5005 S MC 5010 S MCBL 3002 F MCBL 3002 F AES MCBL 3002 P MCBL 3002 P AES MCBL 3002 S MCBL 3002 S AES MCBL 3003 P MCBL 3003 P AES
        • MCBL 3006 S MCBL 3006 S AES MCDC 3002 P MCDC 3002 S MCDC 3003 P MCDC 3006 S MCLM 3002 F MCLM 3002 P MCLM 3002 S MCLM 3003 P MCLM 3006 S MCST 3601
    • Accessories
      • 6501.00065 6501.00088 6501.00096 6501.00097 6501.00113 6501.00121 6501.00135 6501.00136 6501.00159 6501.00283 6501.00284 BC 5004
      • Cables and Accessories MBZ
  • Markets
    • Medical & Laboratory Equipment
      • Cyclotron
      • Rotarex®S-Katheter
      • Air conditioning in incubators
      • Insulin pump
      • Analytical device Gyrolab xPlore TM
      • Laboratory automation
      • Anaesthesia and ventilation system
      • Myoelectric prosthesis
      • Endodontics
      • Prosthetics LifeHand
      • Tattoo machine
      • Sample distribution system
      • Robotic assistant for TMS
      • ViKY (Vision Control for endoscopY)
      • Blood pressure measuring
      • Drug dispenser
      • Diagnostic and therapy capsules
      • XYZ manipulator
      • Controlled prosthetic leg
      • Blood circulation scanner
      • Laboratory analysis systems
      • Microkeratome
      • Blood glucose meter
      • Miniature hexapods
    • Factory Automation & Robotics
      • Yarn winding machine
      • Picker robot TORU
      • Deep-sea robots
      • Inspection robots
      • Zippermast
      • Small parts gripper
      • Industrial robots
      • CHIMP robot
      • Unmanned Ground Ve­­­hicle
      • MROV (Miniature Remotely Operated Vehicles)
      • Humanoid service robots
      • Robotic arm
      • Robotic hand
      • Robot Vehicle
      • Assembly machines
      • Manufacture robotik
      • Sewer Robot
      • Shrimp Vehicle
      • Belt conveyors
      • Electropneumatic Swivel Unit
    • Precision Monitoring & Measuring
      • Dosing pump
      • Test systems for car doors
      • Broadband seismometers
      • Condor Sigma test device
      • Electric field meters
      • Stripping machines
      • Nanomeasurement
      • Horizontal Balancing Machines
      • Precision dispenser
      • Dial Gauge Testing
      • Ring shear tester
      • Geo-Scanner
    • Industrial Tools & Equipment
      • Diode lasers
      • Sensor Screwdriver
      • Inkjet labelling system
      • Electric pruning shears
      • 5-axis CNC unit
      • Adaptive Wire Feeder
      • Solar wafer production
      • Window Wipers
      • Weighing System
      • Linear positioners
      • Pressure pulsations
      • Laser welding
      • Hexapod (Micropositioning technology)
      • Flying-Probe-Systems
      • Printing machine
      • Cutting Plotter
    • Aerospace & Aviation
      • SEIS – Seismic Experiment for Interior Structure
      • Cimon flight assistant
      • Amphibious aircraft
      • Mars Rover
      • Cabin equipment
      • Comet probe "Rosetta Mission"
      • Hexapod
      • Control rocket fuel valves
      • UAVs (Unmanned Aerial Vehicle)
      • Measuring sensor
    • Optics & Photonics
      • Spectrograph
      • Lighthouse optics
      • X-ray optics
      • Pulsed-laser beams
      • Surgical vision systems
      • Microscope Scanning Stage
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