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GPC Y ASOCIADOS S.A.

Veléz Sarsfield 201640 Martinez

Buenos Aires

Tel.: +54 (9) 11 5993 8719

info@gpcasoc.com.ar

https://gpcasoc.com.ar/

Horne Technologies cc

PO Box 536

Betty's Bay, 7141

Tel.: +27 (0)76 563 2084

info@hornet.cc

www.hornetechnologies.co.za

Building of FAULHABER MINIMOTOR SA, Croglio, Switzerland

FAULHABER MINIMOTOR SA

Zona Artigianale 8, Madonna del Piano

6980 Croglio

Tel.: +41 (0)91 611 31 00

info@faulhaber.ch

Building of FAULHABER MICROMO LLC, Wien, Austria

FAULHABER MICROMO LLC

14881 Evergreen Avenue

Clearwater, FL 33762-3008

Tel.: +1 (727) 572 0131

marketing@micromo.com

www.faulhaberUSA.com

NRC Engineering & Precision Drives Co., Ltd.

17F., No. 890, Jingguo Rd., Luzhu Dist.

Taoyuan City 33858, Taiwan, R.O.C.

Tel.: +886 (0) 3-316-1838

info@nrc.com.tw

www.nrc-precidrives.com

EDEL Teknoloji Sistemleri Sanayi ve Ticaret Ltd.Şti

Folkart TowersAdalet Mah.Manas Blv. No:47B/2809

35530 Bayraklı/İzmir

Tel.: + 90 232 215 08 91

info@edelteknoloji.com

www.edelteknoloji.com

Building of FAULHABER Asia Pacific Pte Ltd., Singapore

FAULHABER Asia Pacific Pte Ltd.

Blk 67 Ubi Road 1, #06-07 Oxley Bizhub

Singapore 408730

Tel.: +65 6562 8270

info@faulhaber.com.sg

Compotech Provider AP

Gustavslundsvägen 145, 4 tr

167 51 Bromma

Tel.: +46 (0) 8 441 58 00

info@compotech.se

www.compotech.se

MICROPRIVOD Ltd.

56 (bldg. 32), Shosse Enthusiastov

111123 Moscow

Tel.: +7 495 2214 052

info@microprivod.ru

www.microprivod.ru

Building of FAULHABER Polska sp. z o.o., Poznan, Poland

FAULHABER Polska sp. z o.o.

Ul. Górki 7

60-204 Poznan

Tel.: +48 61 278 72 53

info@faulhaber.pl

FAULHABER Malaysia Sdn Bhd

1A-2-01 & 02 · One Precinct · Lengkok Mayang Pasir

11950 Bayan Baru · Penang · Malaysia

Tel.: +60 4 619 2570

info@faulhaber.my

Swiss Amiet Co., Ltd.

W-903, SK V1 Center, 11 Dangsan-ro 41-g

Yeongdeungpo-gu,07217, Seoul

Tel.: +82 (0) 2 783 4774

info@swissamiet.com

www.swissamiet.com

Shinkoh Electronics Co., Ltd.

Tokyo Sales Office, Motor Sales Division8F, REID-C OMORI building, 6-20-8

Minami-oi, Shinagawa-ku, Tokyo 140-0013

Tel.: +81 (0) 3 6404 1003

motor-info@shinkoh-elecs.co.jp

www.shinkoh-faulhaber.jp

Building of FAULHABER Italia S.r.l., Lomazzo, Italy

FAULHABER Italia S.r.l.

Via Cavour 2

22074 Lomazzo CO

Tel.: +39 0236714708

info@faulhaber-italia.it

Inteltek Automation JV

S.No. 100/5, Ambegaon

Pune - 411046

Tel.: +91 (0) 20 39392150

info@inteltekindia.com

www.inteltekindia.com

Lewenstein Technologies Ltd.

1 Ha'arava St. Givat Shmuel

5400804 Israel

Tel.: +972 3 9780 800

info@l-tech.co.il

www.l-tech.co.il

Electro Mechanical Systems Ltd.

Eros House, Calleva Industrial Park, Aldermaston

Reading, RG7 8LN

Tel.: +44 (0) 118 9817 391

info@ems-ltd.com

www.ems-limited.co.uk

Building of FAULHABER France SAS, Montigny-le-Bretonneux, France

FAULHABER France SAS

Parc d’activités du Pas du Lac2, Rue Michaël Faraday

78180 Montigny-le-Bretonneux

Tel.: +33 (0) 1 30 80 45 00

info@faulhaber-france.fr

www.faulhaber.com

ELMEQ Motor

Passeig Ferrocarrils Catalans 178

Cornellà de Llobregat 08940 (Barcelona)

Tel.: +34 93 422 70 33

marketing@elmeq.es

www.elmeq.es

MOVETEC OY

Suokalliontie 9

01740 Vantaa

Tel.: +358 (0) 9 5259 230

info@movetec.fi

www.movetec.fi

Routech s.r.o.

Dr. Milady Horákové 185/66

460 06 Liberec

Tel.: +420 489 202 971

info@routech.cz

www.routech.cz

Compower ApS

Marielundvej 29

2730 Herlev

Tel.: +45 (0) 44 92 66 20

info@compower.dk

www.compower.dk

Marte Científica e Instrumentação Industrial Ltda

Av Fco Andrade Ribeiro 430

37540-000 Santa Rita do Sapucai, MG

Tel.: +55 (11) 3411 4500

motores@marte.com.br

www.marte.com.br

Building of FAULHABER Drive System Technology (Taicang) Co., Ltd.,Taicang, China

FAULHABER Drive System Technology (Taicang) Co., Ltd.

Eastern Block, Incubator Building, No. 6 Beijing Road West

Taicang 215400, Jiangsu Province

Tel.: +86 (0) 512 5337 2626

info@faulhaber.cn

Building of FAULHABER Benelux B.V., Eindhoven, Netherlands

FAULHABER Benelux B.V.

High Tech Campus 9

5656 AE Eindhoven

Tel.: +31 (0) 40 85155-40

info@faulhaber.nl

Building of FAULHABER Austria GmbH, Wien, Austria

FAULHABER Austria GmbH

Modecenterstraße 22/C89

1030 Wien

Tel.: +43 1 7963149-0

info@faulhaber-austria.at

ERNTEC Pty. Ltd.

15 Koornang Road

Scoresby, VIC 3179

Tel.: +61 3 9756 4000

Fax: +61 3 9753 4000

sales@erntec.net

www.erntec.net

Building of Dr. Fritz Faulhaber GmbH & Co. KG, Schönaich, Germany

Headquarter

DR. FRITZ FAULHABER GMBH & CO. KG

Faulhaberstraße 1

71101 Schönaich

Tel.: +49 7031 638 0

Fax: +49 7031 638 100

info@faulhaber.de

www.faulhaber.com

We are sorry

FAULHABER is currently not represented in the selected country.

Please contact us with your request at

Info@faulhaber.com

Jan-Christopher Mohr

Area Sales Manager

Tel.: +49 (7031) 638 158

jan-christopher.mohr@faulhaber.de

Michael Schütte

Area Sales Manager

Tel.: +49 (7031) 638 456

michael.schuette@faulhaber.de

Daniel Brönnimann

Area Sales Manager

Tel.: +41 (0) 79 570 0814

daniel.broennimann@faulhaber.ch

Rolf Leitner

Regional Sales Manager

Tel.: +41 (0) 79 422 3348

rolf.leitner@faulhaber.ch

Rafael Steinemann

Area Sales Manager

Tel.: +41 (0) 79 932 1645

rafael.steinemann@faulhaber.ch

Brushless Motors in multispot optics for laser soldering and welding

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."

Brushless Motors in multispot optics for laser soldering and welding
Laser beams efficient and precise

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."

Brushless Motors in multispot optics for laser soldering and welding

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.

FAULHABER B
1226 ... B
2 Pole Technology
Data sheet (PDF)
Key Features
Diameter:
6 ... 44 mm
Length:
18 ... 90 mm
Nominal voltage:
6 ... 48 V
Speed up to:
100000 min⁻¹
Torque up to:
217 mNm
Continuous output up to:
282 W
Product details

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