Current status of Disk Lasers for sheetmetal cutting and welding

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Oswald Knight
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1 Current status of Disk Lasers for sheetmetal cutting and welding Iwan Papic, Gerry Jones TRUMPF Luton AILU 12 November 2008 Disk lasers for cutting and welding

2 Presentation outline Disk laser status Latest developments for cutting Latest developments for welding 2

3 TruDisk

4 Beam quality of high power solid state lasers 25 LPSS DPSS BPP [mm mrad] TruDisk Products 2008 TruDisk Products 2009 Disk / Fiber Jan 2008: June not published 2008: Boeing 15 kw > 25 kw nearly diffraction nearly limited diffraction limited Output power [kw] 4

5 Costs of Diode Pumped Solid State Lasers 100% Prices per kw Laser Power 1 kw / Disk 75% 1,5 kw / Disk 2 kw / Disk 50% 2,5 kw / Disk 4 kw / Disk 25% 0%

6 Presentation outline Disk laser status Latest developments for cutting Latest developments for welding 6

7 Twin head flat sheet Disk laser cutting machine 7

8 TruDisk 6001, fusion cutting nitrogen st/st - productivity increase for thin material Fusion Cut NitroLine 10 Vorschub [m/min] Dicke [mm] TruFlow 5000 TruFlow 6000 TruDisk 6001 Values for TruDisk 6001 with one-head operation. Values not yet final 8

9 TruDisk 6001, high speed cutting st/st - clear productivity increase High-Speed Cut 40 Vorschub [m/min] ,5 1 1,5 2 2,5 Dicke [mm] TruDisk 6001 TruFlow 5000 TruFlow 6000 Values for TruDisk 6001 with one-head operation. Values not yet final 9

10 TruDisk 6001, fusion cutting mild steel - comparable performance Flame Cut 7 Vorschub [m/min] Dicke [mm] TruFlow 5000 TruFlow 6000 TruDisk 6001 Values for TruDisk 6001 with one-head operation. Values not yet final. 10

11 Presentation outline Disk laser status Latest developments for cutting Latest developments for welding 11

12 Situation today conventional welding Intensive refinishing Greater warping and distortion Difficult material combinations Difficult to automate Bothersome quality fluctuations Availability problems Potential for improving competitiveness! 12

13 Expanded! The sheetmetal process chain CAD / CAM Cutting Punching Bending Joining 13

14 Flexible laser welding Wide range of joint geometries Corner weld Fillet weld Butt joint Circular weld Lap joint Circumference weld Flange joint Narrow weld Minimal heat-affected zone High reproducibility Little metallurgical material influence Minimal distortion No filler material required High process speed Non-contact working Wear-free 14

15 Heat conduction welding and penetration welding with one tool Heat conduction welding Penetration welding 15

16 Innovative The disk laser Pump laser beam Bending mirror Parabolic mirror Rear mirror Crystalline disk Output mirror Cavity Outgoing laser beam 16

17 Flexible Beam delivery with fiber optic laser cables 17

18 Economical The TRUMPF LASERNETWORK Full use of the laser capacity is made possible by the TRUMPF LASERNETWORK One laser can serve up to 6 different machining stations Each station is connected directly to the laser by means of a fiber optic laser cable and a control cable (field bus system) 18

19 The turnkey solution TruLaser Robot 5020 Robot Workpiece positioner Automation Optics Beam delivery Utility supply Sensors Safety cabin Vacuum extraction CE certification Fixture construction Process integration External programming 19

Best modularity Exhaust system Additional work areas could be defined flexible. Rotational table with various options could be positioned flexible at both sides.

20 Best modularity Exhaust system Additional work areas could be defined flexible. Rotational table with various options could be positioned flexible at both sides. Additional positioning systems available Envelope robot supplier Standard cabinet elements Safety enclosure could be adapted flexible to customers requirements 20

21 Work envelope KUKA KR30 HA 21

Workpiece positioner Example: Rotary-Tilt table KUKA DKP400 Rotary-Tilt table KUKA DKP 400.

22 Workpiece positioner Example: Rotary-Tilt table KUKA DKP400 Rotary-Tilt table KUKA DKP Rotary axis ± 190 Tilt axis ± 90 Working height Rated payload Perm. load torque ML 850mm 400kg 750Nm 22

23 Workpiece positioner Example: Manual rotary table Rotation table Operating mode KUKA rotation table manual, pneumatically supported Rotation range ± 178 Rated payload Workpiece dimensions Loading height 250kg on each side 1400mm x 800mm x 1200mm 800mm 23

24 TruLaser Robot, Welding head Fiber incoupling Motorized focusing adjustment CCD camera Magnetic coupling Cross Jet Shielding gas nozzle (4 tubes or single style) 24

25 Motorized focus adjustment D 1 Collimator lense moveable D 2 Adjustment of focus level 25

26 Damage protection option: Magnetic coupling Robot adapter Catch device Force adjustment Multi-directional damage protection Quick head change Optics adapter plate Magnet housing Release button Excellent repeatability Can be retrofitted 26

27 Option: Laser cutting Full integration in TruLaser Robot Quick change of machining head between welding and cutting Capacitive distance sensor Can be retrofitted The TruLaser Robot cannot be fitted with a cutting table and chamber vacuum 27

28 Option Powder deposition welding Full integration in TruLaser Robot Technology package comprising: - Powder conveyer - Delivery hose - Powder splitter - Focusing optics - Powder nozzle Process control via integrated PLC 28

29 External programming TruTops Cell Import common 3D CAD standard formats Contour preparation and technology data Simulation and collision consideration Integration of fixtures Automatic generation of robot program 29

30 The key to success Laser-friendly design Simplify clamping techniques through suitable design Compliance with tolerance requirements through design solutions Extended design freedom Weight reduction and material savings High accuracy possible 30

31 The key to success Fixtures Why the need for fixtures Ensure a narrow joint gap (< 0.1 mm) Repeat accuracy in workpiece positioning Compensate for manufacturing tolerances Requirements Produce the clamping fixture from flat sheets Try to avoid cutting operations Use standard parts and standard components 31

Practical example 1: Reduced unit costs Dressing 450,00 400,00 Manual welding (WIG / MIG) 350,00-24% YAG laser welding 185 /Std 300,00 250,00 Fixture costs (3 years) 200,00 Bending 150,00 100,00

32 Practical example 1: Reduced unit costs Dressing 450,00 400,00 Manual welding (WIG / MIG) 350,00-24% YAG laser welding 185 /Std 300,00 250,00 Fixture costs (3 years) 200,00 Bending 150,00 100,00 Straightening 50,00 Punching/Laser cutting 0,00 Manually welded cover (3 parts) Laser welded cover (5 parts) Cost reduction: / Cover 87,805.- / year (900 covers) TruFlow resonator cover 32

33 Practical example 2: Reduced unit costs Before After WIG welding 16 min - Laser welding - 3 min Grinding / Polishing 11.4 min - Straightening 15.0 min 2.0 min Total 42.5 min 5.0 min Material: Sheet thickness: Quantity: AlMg3 1.5 mm 180 parts per day Terminal box 33

34 Practical example 3 Fixtures made out of sheets Fixture for laser welding of a box for food industry Stainless steel , t=2mm, with 8 tubes 34

35 Pressure box Company: JÄGER Material: V2A Thickness: S=3+5mm Laser power: 3000W Speed: 1.2m/min Welding time: 180s Dimensions: L290xB230xH200 35

36 Housing for food industry Company: THOMA Material: V2A Thickness: S=1.0mm Laser power: 2000W Speed: 1.8m/min Welding time: 90s Dimension: L360xB250xH85 36

37 Thank you for your attention! Iwan Papic, Gerry Jones TRUMPF Luton AILU 12 November 2008 Disk lasers for cutting and welding

Laser systems: Up to the challenge. Machine Tools / Power Tools Laser Technology / Electronics Medical Technology

Laser systems: Up to the challenge. Machine Tools / Power Tools Laser Technology / Electronics Medical Technology Giving you the edge in laser technology. Contents The most versatile tool in the world.