REMOTE LASER BEAM WELDING WITH INLINE SEAM TRACKING

REMOTE LASER BEAM WELDING WITH INLINE SEAM TRACKING. BMW Joining Technology – Body-in-White FIZ, 11.02.2014 Dr.-Ing. Florian Oefele Christian Roos EA...
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REMOTE LASER BEAM WELDING WITH INLINE SEAM TRACKING. BMW Joining Technology – Body-in-White FIZ, 11.02.2014 Dr.-Ing. Florian Oefele Christian Roos

EALA – European Automotive Laser Applications 2014

REMOTE LASER BEAM WELDING FOR THE NEW MINI. CONTENT.  Motivation  Remote laser beam welding with inline seam tracking  Mini door production  Summary and outlook

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MOTIVATION. STRATEGIC TECHNOLOGY GOALS AT BMW. Strategic goals at BMW

Transformation in car body production

 Lightweight construction and sustainibility

 Innovative joining processes and concepts

 Innovation in Design

 Development of new joining technologies

 Flexibility and transformation ability

 Support of industrial integration

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MOTIVATION. PRODUCTION TECHNOLOGY OF BMW DOORS.

Conventional door production

Aluminium laser door production Aluminium laser welding

Steel laser door production Steel tactile laser welding

Steel laser door production Steel tactile laser welding and remote laser welding

Remote

Tactile

Brazing

Steel and hemming flange Seite 4

MOTIVATION. CONVENTIONAL REMOTE LASER WELDING OF DOORS. State of the art: RLW in overlap configuration with pre-set gap

Advantages  Stabile process with degassing gap  No special position accuracy necessary Disadvantages  Additional costs for setting the gap

 Additional cycle time for setting the gap

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MOTIVATION UND STATE OF THE TECHNOLOGY. RLW IN CAR BODY PRODUCTION. Innovation: RLW of fillet welds Fillet welds allow a stabile zinc degassing and therefore a good weld quality even with zero gap. Fillet weld with zero gap

Lap weld with zero gap

Advantages  No additional costs or cycle time for degassing gap  Small flanges for lightweight construction and design flexibility Disadvantage  High position accuracy necessary Seite 6

REMOTE LASER BEAM WELDING. PROCESS IN DETAIL. Stabile zinc degassing through upper capillary aperture z

Zn

Capillary Melt pool with spatters Solidified melt pool Zn

Loss of weigth by spatters [mg]

yoff

Process window Z275

70

Z100 Z0 DX54

50 30 10 -10 -0,4

0 +0,4 Beam offset yoff [mm] Df = 640 μm, vs = 3 m/min, α = 0°, β = 25°, WS = CR3 Zxx

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REMOTE LASER BEAM WELDING. PRINCIPLES FOR AN INLINE SEAM DETECTION. Light-Section

Grey scale picture for scanner

(Development with SCANSONIC)

(Development with LESSMÜLLER / BLACKBIRD / SCANLAB)

chsheet Upper Lower sheet

 Detection of 3 values / picture  Robust against process disturbances

 Large working distances possible  Integrated process visualisation

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REMOTE LASER BEAM WELDING. DEVELOPMENT AND REALIZATION - ROADMAP. 2011 Supplier BMW FIZ BMW plants

2012 Development Testing BBG

Prototype 32 v. SOP

2013 Optimization Integration Building phase Pre-Series

Prototype 20 v. SOP

SoP MINI 11/2013

Initiator, coordinator, testing

Adaption of scanner optic

Complete Development

Development of control technology Development of sensor

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REMOTE LASER BEAM WELDING. SCANNER WITH INLINE SEAM TRACKING. Laser Camera

Illumination

SCANSONIC

RLW-A

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REMOTE LASER BEAM WELDING. SCANNER WITH INLINE SEAM TRACKING. Laser Camera

Illumination

SCANLAB intelliweld 30FCV LESSMÜLLER weldeye remote BLACKBIRD RSU remote (not shown)

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SYSTEM ACHITECTURE. SCANNER WITH INLINE SEAM TRACKING. Lessmueller Properties for seam detection: ( Illumination duration, exposure time, etc. …)

Blackbird Properties for welding /communication: (Process parameter, seam numbers, error handling, etc. …)

Laser

Remote Laser beam welding with inline seam tracking Dr.-Ing. Florian Oefele, Christian Roos - 11.02.2014

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MINI DOOR PRODUCTION. JOINING CONCEPT. Joining proceses Closing plate

 Tactile Laser Welding (outer skin with inner door panel)

Inner door panel  Remote Laser Welding (Closing plate with inner door panel)

Outer skin Seite 13

MINI DOOR PRODUCTION. LAYOUT OF THE PRODUCTION PROCESS. Spot welding (for Positioning of Closing Plate + Inner Door panel)

Cycle time: 58 sec.

Tool Storage

Process time for Remote Welding: 28 sec.

Remote Welding

Tactile laser welding (Outer Skin)

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MINI DOOR PRODUCTION. MATERIAL AND SEAM CONCEPT. 27 to 31 weld seams / door Closing plate (DX54D Z100 0,8 mm)

1.1 m seam length / door

Inner door panel anel (DX54D Z100 0,8 mm)

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MINI DOOR PRODUCTION. FRONT DOOR. Live Camera

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MINI DOOR PRODUCTION. PROCESS PARAMETERS. Joining geometry  Fillet welds with zero gap  CR3 Z100 (0,8 mm)

Laser source and optic  TRUMPF TruDisc4001  Scanlab INTELLIWELD 30 FCV

Process parameters  PL = 1,8 kW  vS = 3 m/min  D = 800 μm

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MINI DOOR PRODUCTION. CHALLENGES. Accuracy of beam positioning

Clamping

(Tolerances in car-body-production of ± 0,5mm)

(implementing zero gaps)

± 0,5 mm

Seam

Yoff Spanner Clamp

Seam tracking

Stabile process

(variable edge geometry, surfaces and conditions)

(Crossjet, protection glass, exhaustion)

hS

hG Seite 18

SUMMARY AND OUTLOOK.  New process and system technology for RLW of fillet weld in car body production was presented.

 For the new MINI the process is industrially implemented with an inline seam tracking and correction on basis of grey scale image evaluation.  Control of edge geometry and process conditions are crucial for a robuste seam detecion and an accurate beam positioning.  About 1 m of RLW seams per door increase its stiffnes and realize a lightweight construction with small flanges.  Further development of the sensor system aim to integrate additional functions concerning quality control. The process will be developed for new materials and applications.

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