Weight laser housing: 54 kg
laser Power 1600 Watt continue (CW)
Fiber Welding Cable 5/10/15 m
Dimensions of laser housing: h x w x d : 570 x 300 x 650 mm
- Electric connection : 220V 16A mono
Air cooled (with heath pump)
Ultra energy savings
Wall plug Efficiency : almost 50% = highest efficiency in it's class
Robotic welding is one of the most common robotic applications in the industrial sector, being driven mainly by the automotive sector for the last several decades. Robotic welding is most productive when completing high-volume, repetitive welding tasks. With the new flexible robots and cobots small batch production and even single part production is in reach of any robot with Wobble-R Fiber laser welding units from Lasermach.
With robotic welding integration, you can:
- Decrease Employee Risk to Burns & Hazardous Fumes
- Increase Quality & Consistency of Welds
- Decrease Time Required to Finish The Job
- Decrease Space Needed to Perform Tasks
- Decrease Labor Costs
with integration of our predefined Wobble-R units, you can:
- Decrease even more Employee Risk to Burns & Hazardous Fumes
- Increase Quality & Consistency of Welds
- Increase drastically the welding speed
- Decrease Time Required to Finish The Job
- Decrease on a huge scale the post processing of your welded parts
- Decrease drastically Labor Costs
- Decrease Heat-affected zone (HAZ)
The market for robots is steadily growing across the world, and Europe has an excellent tradition both in terms of construction and integration of robotic automation systems in production plants. The sectors that absorb the most production and use of industrial robots are: automotive, electronics, metals, and plastics. The inclusion of robotic islands in the industrial context has changed the production cycle of many companies, increasing the quality of products and the speed of processing, thereby cutting costs and reducing safety risks for operators.
Welding and Robots: how are we doing?
The islands are usually used for handling, assembly, painting and welding. Handling is the primary field in robotics use, with a global share of 44%, while robots used in the welding sector account for 37% (spot welding, laser welding, etc.).
The Metal sector has shown considerable interest in technological innovation in terms of increasing production and use of automation. This has led to a dynamic trend in all markets, with a high percentage of robot sales and automated systems. Indeed, annuel root consumption increases by 12~22% compared to the previous year.
It is recognized that automated welding produces high quality and repeatable joints while reducing heat production, slags and, wastes during the process. The use of a welding robot avoids oversized joints, since the systems are programmed with parameters that allow to joint production with precise dimensional characteristics, avoiding expansion or contraction processes in the surrounding metal during heating and cooling cycles.
Automated systems guarantee high reproducibility and shorter cycle times in welding processes, reducing the consumption of resources and electricity compared to manual processes, thus meeting the growing need for energy efficiency. The speed of the machines is about five times higher than the average man, not to mention that the robot can move quickly from one joint to the next, allowing the execution of several operations in series.
Automation reduces labour costs and compensates for the shortage of skilled welders, as less practice is required. Therefore, the welder becomes a process monitoring operator.
Flexibility also extends to the variety of process types and joints that can be manufactured based on a variety of materials and components. Generally speaking, the robotic stations are equipped with a repository with various welding programs that can be used on different materials and thicknesses, for example MIG, MAG and TIG. Here it is possible to install standard robots, hollow wrist robots, robots with push-pull torch or with master-slave system.
In particular, it is worth mentioning how welding benefits considerably from the use of collaborative robots (cobots), which carry out the tasks alongside the operators in the assembly lines. Cobots estimates indicate average annual growth of more than 50% until 2026. While large companies are mainly interested in installing fast-working robots in their production lines in order to maximize productivity, the cobots are more suited to the needs of small and medium-sized companies. They are slower and more flexible since they have to learn, repeat, and save movements to be carried out from the operator. In essence, the robotic arm is able to replicate, the work that a highly qualified welder would do with greater quality and in less time, implying additional health and safety benefits.
Welding requires repetitive and precise torch movements. As such, the welder’s fatigue is not an inconsiderable problem. This physical condition can lead to musculoskeletal disorders. By placing a robotic arm next to the human, fatigue is drastically reduced as the torch is manipulated by the cobot. The welders are only required to monitor the process and guide the torch where necessary. The ergonomics of the working environment is considerably improved, since the use of robots allows to avoid welding in forced positions. This prevents stress to the operator’s body and limbs experienced during manual work and risky for their health.
Carrying out the operation with the help of a robot protects the operators’ health, preventing them from being exposed to the UV/IR light generated by arc welding, which can cause visual disorders, as well as long-term carcinogenic pathologies generated by continuous exposure to smoke and toxic gases. In particular, the use of collaborative robots allows better control of emissions, thereby reducing the environmental impact.
There are considerable benefits in terms of joint quality, since the use of a robotic arm guarantees a defect rate of less than 3%, avoiding additional work processes. It is not necessary for the operator to act manually to file or roughen the beads released from the welding material or to repeat the work, using a gas torch if any defects have to be eliminated. The cobots’ precision combined with optimized welding power avoids the use of additional welding wire which causes energy and material waste. By reducing the quantity of defects and using adequate power, the use of a cobot allows to considerably reduce the consumption of gas to maintain the flame active. CO2 emissions into the environment are lower. In this regard, it should be noted that welding accounts for 4.5% of the European Union’s gross energy consumption, and arc welding produces 9.82 grams of CO2 per second.
Robotic laser welding has emerged as a highly productive automation solution over the past few years. It offers a number of advantages over traditional welding processes and can be used in completely different types of applications.
Robotic laser welding delivers precise and clean welds, whereas other methods of welding are more prone to inconsistencies and may leave inaccurate welds, even when paired with robotic automation technology. Laser welding is also more versatile, working with a wide range of metal thicknesses. It can be faster than traditional welding and has a significantly smaller heat-affected zone, minimizing distortion of parts during welding.
Robotic laser welding works slightly differently than traditional welding methods. There are two types of laser welding: heat conduction laser welding and deep laser welding. Heat conduction laser welding is used primarily for thin parts. In this process, energy gets into the workpiece through heat conduction. The materials melt at the point of the weld from this conducted heat and then quickly solidify, sealing the material.
Deep laser welding works by melting the material and creating a deep steam capillary, also known as a keyhole. This steam capillary moves with the laser as the weld is made, allowing the weld to reach deep into the material. The melted material solidifies behind the steam capillary and permanently seals the material.
Robotic laser welding is used in applications that require clean and precise welding. The accuracy and low heat generation of laser welding make it ideal for welding thin or delicate materials without causing distortion or spatter. The manufacture of medical devices, for example, uses laser welding because there’s no material contact, no spatter, and a high degree of weld consistency.
Similarly, robotic laser welding is used in applications that have limited access to the part. Laser welding robots, unlike traditional welding robots, do not actually need to touch the part. Some laser welding robots can weld from over a foot away from the part. This makes accessing hard-to-reach areas much easier.
Robotic laser welding offers a number of benefits over traditional welding in certain applications, depending on the nature of the part. It’s an innovative way to weld metal materials and it’s been gaining popularity in a wide range of industries and applications.
Laser welding has emerged as one of the top applications for robotic automation. Laser welding is unique to other welding applications since it uses a laser instead of an electric arc for joining metals together.
The top benefits of automating laser welding with industrial robots include:
- Cleaner Welds - Laser welding is a precise welding method, even more so when automated with welding robots. Articulated robots operate with high repeatability, steady movements, and with incredible path accuracy. Automating with the robots or cobots reduces spatter, resulting in a smooth, clean weld. Robotic laser welding increases first-run weld quality reducing the need for touchups or rework.
- Small Heat Affected Zone - Robotic laser welding uses a much smaller heat affected zone (HAZ). Not only is the heat affected zone smaller, but less heat is needed to join metals together. The robot or cobot is able to use a small heat affected zone while using lower temperatures and maintaining control over the temperature of the laser for consistent heat. A smaller heat affected zone and better temperature control reduces the risk of workpieces becoming distorted.
- No Material Contact - Unlike other robotic welding applications, laser welding robots are able to weld parts without having to touch them. The robot or cobot can laser weld parts without making contact, allowing for easier access to hard to reach workpieces. Some laser welding robots can weld from over a foot away, making them ideal for welding parts located in confined spaces. Not making contact with the materials also helps to prevent part distortion along with a small HAZ.
- Versatile - Robotic laser welding is extremely versatile. Laser welding robots can work with a variety of metal types and metal thicknesses. The small heat affected zone and low temperatures make robotic laser welding ideal for thin metals. Laser welding six axis robots can also weld thick metals by creating a deep steam capillary. This method can even weld metals that previously were not considered weldable, such as exotic metals prone to cracking, since less heat is used.
- Rapid Thermal Cycle - Automating laser welding with robots allows for a rapid thermal cycle that happens within a few milliseconds. This not only speeds up the welding process but produces a more durable weld. A rapid thermal cycle creates a better weld structure which has better mechanical properties. The weld will be more resistant to corrosion, will be stronger, and less likely to deteriorate.
- Faster Cycle Times - The robot/cobot operates at much faster speeds than a welder. Parts will be welded in less time than with manual laser welding. The elimination of touchups or rework due to the accuracy of laser welding robots further shortens the length of time to weld each part.
- Safer - Manual laser welding can be dangerous to workers, especially since the laser is not visible. Automating with welding robots eliminates safety risks from workers. Laser welding robots can be contained in robotic workcells creating a safeguarded work environment that protects workers from exposure to the laser beam.
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Lasermach new product PhotonWeld-R with the Wobble-6R-PRO+ high-power wobble welding head is released! It highly integrates high-power two-dimensional scanning galvanometer, control system, human-machine interface, observation camera, QBH, collimator lens, focusing lens and other optical components. It does not need an external controller. It can directly control the galvanometer and laser, and supports external IO triggers to start and supports secondary development of customer remote interface. It can be widely used in high-end processing fields such as laser welding and laser quenching of wide welds. The system is stable and reliable, compact in structure, precise in optical path, good in sealing, exquisite appearance, light in weight and easy to install.
The new PhotonWeld-R power swing welding system supports linear, rectangular, circular, elliptical, figure 8 and other swing modes, each of which is adjustable in length and width; supports rotation, and each mode can modify the rotation angle online according to the welding path; The mode supports the independent setting of the power on both sides to support the user's research and implementation of complex processes; it supports the storage and import of 64 sets of programming parameters, which can be combined freely, giving users the flexibility to program different welding paths.
The PhotonWeld-R can provide a wealth of interfaces and DEMO development codes, support MODBUS protocol, and support customers to quickly integrate all controls into their own main control software. It also supports laser alarm shutdown, online recording of temperature curves in 3 key temperature zones, and abnormal alarm shutdown. It uses high-speed high-performance scanning galvanometer, high swing frequency, faster welding speed and higher efficiency. It will be your better working partner for high-end welding!