The AWL laser-welding portfolio

The AWL laser concepts are designed to offer you the best balance in price/performance. In order to meet your specific requirements, AWL has developed a large laser-welding portfolio of machine configurations.

AWL and welding systems
Since 2002, AWL has been actively involved in the development of various laser-welding concepts. During this period we have always kept the focus on high speed, flexibility, reliability and economics. From diode laser welding to CO2 laser welding and from YAG laser to fiber laser welding, AWL has realized multiple laser solutions. These solutions are most commonly used with these welding systems:

1. Remote overhead system | The first welding system is the remote overhead system. A specific solution which offers short weld-to-weld times and is laser-source independent. It is a very solid solution. It’s a perfect match for products that have small welds, close to each other in a 2,5D area (limited reach ability).

2. Remote focusing optics with robots | The second welding system is a remote scan head mounted on a robot. It offers great path accuracy while retaining high welding speeds. The short weld-to-weld times offer a high laser up-time. This solution is best suitable for products with small welds, close to each other (3D). This way the the product is reachable from every angle.  It also gives you the opportunity to weave and mark.

3. Fixed focusing optics with robots | The third welding system consists of one or more robots with fixed optics. It offers a great reach ability, high path accuracy and excellent flexibility. The advantage is even greater if you weld with multiple robots, better known as the AWL beam-switch concept. As the beam switches from one optic to the other, a very high laser uptime is established. Products that are suitable for this configuration have relatively long distances between the welds and the welds are in various angles (3D). Recent developments with fiber laser and the significant improvement of robot safety offer serious robotized laser-weld possibilities.

For specific laser welding regulations AWL also supplies tailor made solutions. In the past decade we have gained a lot of experience in these so called specials.

AWL and the logistical concepts
Because laser welding is a very fast process, the demands for the logistics in the machine will be much higher, enabling you to retain the best balance in your machine. AWL has almost 50 years experience in automated welding and the integration of logistical processes. Our concepts are are based on proven building blocks, making them very reliable.

Our mechanical, electrical, robotic, control, process optimization and project management departments all work together to develop the optimal configuration for your turnkey machine. These projects include the integration of the machine with its logistics and fixtures and the welding process optimization, the erection and commission on your premises.

As a system integrator we have the ability to create the ideal machine for your specific requirements. AWL designs these optimal configurations by using a library of proven standard building blocks. If necesary we engineer specific customized parts. It doesn’t matter if you are looking for a configure-to-order solution or an engineered-to-order solution; AWL keeps you ahead in automated welding.

In principle we can describe five basic logistical concepts:
1. Compact principle | This cell comprises one robot and two insert and weld positions. Welding can be done on a ‘fixed’ fixture position, but also on a rotating fixture through the use of external robot axes.

2. 2-way index table principle | With this principle the efficiency is raised by having two fixture positions on one index table. Two robots weld the product while the parts insertion and product removal is carried out by the operator.

3. 4-way index table principle | This principle has four positions on one indexing table. Therefore you are flexible in the purpose of the position. Often the balance is two positions for insertion of the parts, one welding position and one position for automated product removal.

4. Slide table principle | The sliding concept provides the highest laser uptime. The fixtures are set on a table that slides in and out the welding position, just as bread slides into an oven. The welding position switches from one table to the other. This principle is very suitable for the automation of the logistics.

5. Shuttle principle | The shuttle concept has either one or two robots on one track allowing them to move along the fixtures for welding.

All these logistics layouts have many variations. From compact to very extensive layouts.

Based on this portfolio customers and AWL discuss and develop different logistical variations and new logistical principles for the optimal customer requirements.

Developments
The two directions, welding systems and logistical concepts will be the basis for future developments; the right integration standards for new welding systems, for example the upcoming diode laser, and optimum routing for the new logistical layout. All developments that fully exploit the laser-welding process to help AWL’s customers stay ahead in automated laser welding.