Technology advantage: Machine dynamics Evolution of machine dynamics 1000 a
Axis speed v [m/min], Acceleration a [m/s2 ]
v 100
Brushless servo motors Linear drives
10
R
DC motors
Rmin 1
v2 ? a
Example: Example: aa == 22 m/s aa == 20 m/s22 20 m/s m/s22 vv == 20 vv == 20 20 m/min m/min 20 m/min m/min R = 54,4 mm R min == 5,5 Rmin 5,5 mm mm min = 54,4 mm Rmin
Source: TRUMPF 0.1 1990 1995
2000
2005
Year
The TRUMPF Group
TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 1
Laser Cutting: Success in parallel technologies ? Today laser cutting has replaced plasma cutting and water jet
? ? ?
? ? ?
cutting for flexible sheet metal fabrication because of superior speed and edge quality Punch nibbling is still around (20-30% market share) It took 20 years to become the dominant sheet metal fabrication technology It took equal advances in laser physics, rugged industrial source design, machine and drive development, application development, market acceptance to write this success story Reliability and profitability were key to the success – the machine operator doesn’t want to worry about the laser Constant profitability increase allows further market growth (12% CAGR of the last decade for TRUMPF) -> avoid market saturation Today laser cutting has created the third largest single laser source market ($435 Mio.) behind optical storage ($1400 Mio.) and telecom ($670 Mio.), but before medical ($380 Mio.)
The TRUMPF Group
TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 2
Transforming physics into profits ? About TRUMPF ? Case Study 1: Telecommunication Laser Diode
Understanding volume manufacturing
? Case Study 2: Laser Cutting
Parallel technologies
? Case Study 3: Laser Welding
Understanding customer requirements
? Case Study 4: Laser Welding
Prove your technology
The TRUMPF Group
TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 3
Today’s biggest markets for laser sources
1600
Revenues 2002 [TUSD]
1400 Diode 1200
Excimer Solid State
1000
CO2
PPFF M UM TTRRU
800 600 400 200 0 Optical Data Storage
The TRUMPF Group
Telecommunications
Solid-State Laser Pumping
Medical Equipment
Materials Processing
TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 4
Market Drivers for Laser Material Processing in the automotive Industry Trends in Production Automation Flexibility Quality
Product Trends Miniaturization Quality
Laser Technology
New Features
Improved Lasers Improved Systems Improved Processes
The TRUMPF Group
TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 5
Market Drivers for Laser Material Processing in the automotive Industry Consumer Trends in Production Automation Flexibility Quality
Product Trends Miniaturization Quality
Laser Technology
New Features
Improved Lasers Improved Systems Improved Processes
The TRUMPF Group
TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 6
Laser welding: Body in White (BIW) Volkswagen Passat and Golf: Roof seam welding with 4 kW Nd:YAG-Laser
Seam Geometry Only laser allows seam welding: • Sealed roof -> no rubber seal -> improved painting operation • Stiffness -> improved crash performance -> improved handling The TRUMPF Group
TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 7
Market Drivers for Laser Material Processing in the automotive Industry Consumer Trends in Production Automation Flexibility Quality
Product Trends Miniaturization Quality
Laser Technology
New Features
Improved Lasers Improved Systems Improved Processes
The TRUMPF Group
TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 8
Nd:YAG Laser: 3 D Welding applications
Laser Source: 350 - 4500 Watts cw & special pulsed applications
Flexibility: Fiber Optical Beam Delivery
Especially well suited for 3D welding applications
The TRUMPF Group
TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 9
Market Drivers for Laser Material Processing in the automotive Industry Consumer Trends in Production Automation Flexibility Quality
Product Trends Miniaturization Quality
Laser Technology
New Features
Improved Lasers Improved Systems Improved Processes
The TRUMPF Group
TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 10
Trends in Production: Flexibility Optimized utilization of the laser sources, support of several working stations and redundancy.
Nd:YAG-Laser in Car Body Production: LaserNetwork The TRUMPF Group
TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 11
BIW laser welding utilizing TRUMPF Lasers within European Car Companies ? ? ItIttook tookmore morethan thanaadecade decadetotofully fullyimplement implementlaser laserwelding weldinginin
94 /95 95 /96 96 /97 97 /98 98 /99 99 /00 00 /01 01 /02 02 /03
# of TRUMPF lasers
the automotive theEuropean European automotiveindustry industry 700 What to happen: Whathad had to happen: 600 ? Development ofofreliable laser sources and ? At AtTRUMPF: TRUMPF: Development reliable laser sources and 500 constant constantimprovement improvement 400 ? ? At AtUniversities, Universities,Institutes: Institutes:Development Developmentofofapplications applicationsthat thatadd add 300 value value(e.g. (e.g.roof roofseam seamwelding) welding) 200 ? ? At Atcar carmanufacturers: manufacturers: 100 ? applications ?Reproduce Reproduce applicationsinincompany companylab lab 0 designers, find value added ? ?Educate Educate designers, find value added ? ?First Firsttimid timidsubstitutions substitutionsofofnon-critical non-criticalspot spotwelds weldswith withlaser laser welded weldedseams seams ? ?Increase Increaselength lengthofoflaser laserwelded weldedseam seamon onBIW BIW # of laserswelding sold into BIW next Installation Base ? ?Fully Fullyreplace replacespot spot weldingwith with nextmodel modelchange change The TRUMPF Group
TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 12
BIW laser welding in North America. ? ? In Inthe theUS USmarket marketthe theintroduction introductionof oflaser laserwelding weldingoccurred occurred
# of Lasers
already alreadyaadecade decadeearlier earlierthan thanininEurope. Europe. 350 ? ? Promises Promiseswere weremade madewith withregards regardsto: to: 300 ? ?Reliability Reliability 250 ss!! d ? Process e d ? Processcontrol control eee n 200 s n r eers ? m ?Profitability Profitability o m t ssto 150 u c u r ? Enhanced functionality uur c ? Enhanced functionality o y o 100 y ttooapplication n ? Laser technology, development, customer e n t ? Laser technology, application development, customer e s i t 50is L requirements L were requirements werenot notready readytotosupport supportthese thesepromises promises 0
94 /95 95 /96 96 /97 97 /98 98 /99 99 /00 00 /01 01 /02 02 /03
? ? The Thegeneration generationof ofplant plantmanagers managersthat thatburned burnedtheir theirfingers fingerson on
the thefirst firstattempt attempton onlaser laserwelding weldingare arenow nowfinally finallystarting startingtotogive give lasers lasersanother anotherchance. chance. # of lasers sold into BIW
The TRUMPF Group
Installation Base
TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 13
Aluminum Welding in Aerospace Welding with CO2- and Nd:YAG-Laser
Advantages laser welding compared to riveting: • increased speed • increased stiffness • less corrosion The TRUMPF Group
TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 14
40 35 30 25 20 15 10 5 0 94 /95 95 /96 96 /97 97 /98 98 /99 99 /00 00 /01 01 /02 02 /03
# of Lasers
BIW Laser welding within the Aerospace Industry
# of lasers sold into Aerospace
The TRUMPF Group
Installation Base
TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 15
Transforming physics into profits ? About TRUMPF ? Case Study 1: Telecommunication Laser Diode
Understanding volume manufacturing
? Case Study 2: Laser Cutting
Parallel technologies
? Case Study 3: Laser Welding
Understanding customer requirements
? Case Study 4: Laser Welding
Prove your technology
The TRUMPF Group
TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 16
Construction of a lamp pumped cavity Cavity of a high-power solid-state laser
Lamps
Rod
Nd:YAG - rod
Principle: Double elliptical reflector
Krypton lamps
The TRUMPF Group
TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 17
Efficiency of a Lamp Pumped Nd:YAG Laser Electrical Input
Power in Pump Bands
Thermal Loss of Lamps: 50 %
Absorption - Cavity 30% - Water, Flow Tubes 7% - Nd:YAG Rod 5%
Optical Loss: - Reabsorption in the Lamps 5% - Fluorescence 0.4% - Resonator Losses 0.6% Optical Output
The TRUMPF Group
TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 18
Absorption of the Nd:YAG / Emission of the lamp 808 nm
Wavelength in nm
Absorption Spectrum of Nd:YAG
Emission Spectrum of Krypton lamps Krypton arc lamp Laser diode with central wave length of 808 nm
Wavelength in nm
Wall plug efficiency: Lamp pumped Nd:YAG laser: Diode pumped Nd:YAG laser: CO2-laser: The TRUMPF Group
808 nm
2% 15% 10% TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 19
Unmounted Diode Laser Arrays
Mirror / Facet
P- Side Broad Area Emitters
The TRUMPF Group
TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 20
Thermal Management: Micro Channel Cooler
cw output power [W
Micro Channel Cooler Array reported records
commercially available
Year The TRUMPF Group
Micro Channel Cooler: Brazed water manifold TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 21
Structure of a pump module 11 Diode lasers per pump module 5 pump modules per cavity Cathode of the diode Anode of the diode Glass plate guides light to the rod Reflector
Integrated “Flight recorder” The TRUMPF Group
TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 22
Principle of a cavity for a diode pumped Nd:YAG Pump module
Reflector
Glass tube
Glass plate guides the light of the diodes
Diodes The TRUMPF Group
Laser rod
Cooling water
TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 23
Diode Pumped Solid State Nd:YAG Lasers Side Pumped All Solid State Rod Laser 6 Cavities 30 Pump modules 330 Diode Lasers
Cavity
Laser Power: 6 kW Plug Efficiency: 15 %
Pump module
The TRUMPF Group
TRUMPF is one of the first laser manufacturers world-wide to deliver reliable multi-kW diode-pumped Nd:YAG Lasers
TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 24
Diode pumped cw solid state lasers up to 4500 W Type
The TRUMPF Group
Pump chamber
Laser power at the workpiece [W]
Beam quality
[Amount]
Max. power output [W]
HLD 1003
2
1300
1000
12
HLD 2304
4
3000
2300
16
HLD 3006
4
4000
3000
25
HLD 3504
6
4500
3500
16
HLD 4506
6
6000
4500
25
[mm · mrad]
TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 25
Diode pumped high power Solid State lasers ? High power diode lasers promise an order of magnitude less
energy consumption. ? They are available from one of the most trusted names in lasers and the currently only supplier of high power solid state lasers into automotive manufacturing: TRUMPF ? Still a large car manufacturer chose to place the largest order in
the history of high power solid state lasers on lamp-pumped systems. A power plant for these lasers will be installed
? Reliability outweighs any promised benefit by disruptive
technologies ? There are no shortcuts: Prove your technology!
The TRUMPF Group
TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 26
Transforming physics into profits ? About TRUMPF: The future ? Case Study 1: Telecommunication Laser Diode
Understanding Volume Manufacturing
? Case Study 2: Laser Cutting
Parallel technologies
? Case Study 3: Laser Welding
Understanding customer requirements
? Case Study 4: Laser Welding
Prove your technology
The TRUMPF Group
TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 27
TRUMPF Sales in Million Euro 1400 1200 1000 800 600 400 200 0 91/92
92/93
93/94
TRUMPF total
94/95
95/96
96/97
97/98
98/99
99/00
TRUMPF Laser related business
00/01
01/02
* 02/03
TRUMPF Lasers
* Forecast The TRUMPF Group
TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 28
Million US-$
Market Review: Applications of lasers sources
The TRUMPF Group
TH150sn - Unternehmenspräsentation - 09.10.2002 E, US$, 29
Die TRUMPF Gruppe
Thank you for your kind attention!
