Operational: Beam Switch
In 2011, AWL delivered the first laser welding machines that use the beam-switch management system, in which two robots are equipped with two fixed optics but together only use one laser source. While one robot welds, the other robot moves to the next welding position. When one robot has finished welding the laser is switched and the other robot can immediately start welding.
One of the companies using the AWL laser welding machines is Brose.
Brose is a major supplier to the international automotive industry and was among the first organizations to weld their products using laser technology. Although Brose has an extensive and capable internal engineering and construction department, it was decided, because of the growth expectation that Brose has and the actual order intake, to outsource the building of the laser welding machine.
After several intense rounds of discussions and proposals, AWL was asked to build these machines. The reason for choosing AWL was the high level of knowledge in the field of laser welding, the pleasant communication, the concept presented and the fact that AWL is also present in the Czech Republic, where one of the largest factories of Brose is situated
Apart from being a unique selling point, AWL having all the in-house skills and ability to integrate the machine, the fixtures and the process is of great convenience to Brose. Brose is known as a highly professional organization that regards speed and quality of paramount importance. These values are also required from their suppliers. Brose's focus is on premium cars, the higher segment, which places high demands on product, service and quality.
Large volume
The machine that AWL built for Brose was developed for two large platforms. The machine is capable of producing large volumes. The configuration consists of a cell, an automatic laser welding station and a buffer station. Operators are used for the supply of parts. When the product has been welded, the handling robot removes it from the fixture and places it on a transportation belt.
Safety and Quality
The machine is a stand-alone system which uses a double cell with spy sensors for safety reason. The index table and the welding robots are mounted on a steel frame. A suction system is placed in the roof to extract the smoke and gases released by laser welding. In addition, air purifiers are connected in the fixtures.
Features of the laser welding cell are:
- Full 3D editing possible
- Loading and welding of multiple product variants
- Loading station operated by two people
- Automatic unloading
- Robotic gripper with quick change
Dimensions of the machine
- Width approx. 7000 mm
- Depth approx. 7500 mm
- Height approx. 3800 mm
- Working height approx. 1050 mm