Audi advocates an optimized manufacturing of Trumpf technology

Conventional welding with solid lasers has become the standard process of Union of pieces for the construction of vehicles in the automotive sector. The development of this process has culminated in laser welding is possible with scanner by robot, unite movement of a robotic arm articulated with highly dynamic positioning movements of a laser scanner. Audi uses this new technique for the manufacture of high performance for the first time for the production of the doors of the new Audi A4.

Among the most important challenges encountered during the development and improvement of this process is the availability of sources appropriate laser, the quality of the beam was of special importance in this regard. Barcode systems pumped by lamp equipped with a beam of 25 mm.mrad quality demonstrated its suitability on numerous occasions in the various conventional applications for welding by laser. With a few values that clearly surpass 99 percent these laser sources set new standards in regards to performance. For welding laser scanner is needed, however, with a significantly better quality laser beam. This is due to the size of the surface of mechanization of an optical system by scanner and the distance of viable work depend directly on the quality of the beam. Given that the potential derived from the geometry of the bars in regards to the quality of the beam is exhausted, it has only been possible to comply with the requirement of an improved quality laser beam introduced a new laser concepts. In recent years Trumpf Laser has further developed the laser disc into a product suitable for industrial applications, which is already being used successfully worldwide.

Thanks to its bundle of standard quality of 8 mm * mrad disk laser is used currently in the range of up to 8 kW power for all laser applications, from laser cutting, until the welding conventional passing through the laser scanner welding.

Another new development of Trumpf is an optical system by scanner suitable for industrial uses for this range of power. So far is the only robotic solution that complies with the hard evidence of qualification of the German automotive industry and already can be found installed in series production. Daimler Chrysler has recently incorporated the process in the construction of the bodies of their new vehicles. For its part, Audi soldering laser since January 2007 with the new technique and can thus continue with the good results obtained with the applications of welding used laser so far.

The advantages compared to conventional processes reside primarily in a substantial improvement in productivity. A simple and rapid movements of the mirrors of the optical system by scanner decrease usual required time for the positioning of robots and considerably reduce the total time of development of the process.

About 0.5 points of weld per second, with welding by laser scanner are available in comparison with the welding resistance with which it is possible to average performing of three to four spot welds per second. In this way can increase considerably the degree of use of laser sources and thereby a significant improvement in profitability. The high efficiency of the disk laser guarantees also low costs of operation of the laser source. A typical performance of the 25 per cent decrease energy costs over pumped by lamp systems and requires the user requirements much lower with respect to the infrastructure facilities.

Development of Audi and VW engineers studied the benefits of the process of welding by laser scanner. One of the most important problems encountered was the technique of subject and the preparation of the pieces. During the development process, Audi managed to resolve these difficulties so that today the production quality is undoubtedly excellent.

The Trumpf group is specialized in the production and development of lasers and systems lasers for application in manufacturing technique

Trumpf PFO 33 (Programmierbare Fokussier Optik: programmable optical system)-first optical system for robotic scanner used in the series in the German car industry production for the welding of body components.

TruDisk 6002 - laser Trumpf disc with an initial power of 6 kW, a radiator compression integrated and maximum 6 outputs

Audi experts developed a pre-treatment by laser components which guarantees a high quality of the sewing of welding despite the zinc coating. ND: YAG pulse of Trumpf lasers are used as useful.

Through a pilot implementation in the framework of the current manufacture of the Passat Consortium VW has already certified in 2005 the process and the components of the system of the welding by laser for series production scanner.

Already at that time was a very good operation of the components of the system and the improved profitability of the process was tested. Now, Audi has proceeded to consistently implement the process in series production. Already since the beginning of 2007 the gates of the new Audi A4 is welded with an optical scanner system and the disk of 4 kW of Trumpf laser.

Thanks to this new technology, it is possible to produce 1,800 doors a day with only four cells of machining. Each team of scanning has a TruDisk 4002 of Trumpf. This is the latest generation of disk lasers. The initial power of 4 kW in the work piece occurs through two albums only.

And Audi advocates the benefits of the Laser Network (TLN) from Trumpf, which makes it possible to random lasers interconnection, so that the proper functioning of the teams is guaranteed even in the case that is averíe a laser.

Trumpf, business group: technology laser Trumpf group is a leader in the production and development of lasers and systems lasers for application in manufacturing technique.

Its product range includes high power CO2 lasers, solid lasers pumped by diodes and lamp, marking lasers and laser of several axes systems.