Product Overview
The In-Line Laser Welding System seamlessly integrates fiber laser technology, precision motion control, automated material handling, and smart MES connectivity. Designed to replace labor-intensive traditional welding, it delivers up to 4-5x faster welding speeds, eliminates thermal distortion, and guarantees 99.5%+ product yield rates in continuous multi-shift operations.
Technical Specifications
|
Item |
Specification |
|
Laser Type |
Fiber Laser |
|
Laser Power |
1000W - 6000W Optional |
|
Laser Wavelength |
1080nm |
|
Welding Mode |
Continuous Welding / Pulse Welding |
|
Applicable Materials |
Stainless Steel, Carbon Steel, Aluminum, Copper, Galvanized Steel |
|
Material Thickness |
According to material type, laser power, and welding requirements |
|
Welding Speed |
Customized according to application |
|
Positioning System |
Servo Motion Control |
|
Fixture System |
Customized Precision Fixture |
|
Automation Level |
Semi-Automatic / Fully Automatic |
|
Control System |
PLC + Industrial HMI |
|
Cooling System |
Industrial Water Cooling |
|
Safety Protection |
Enclosed Welding Area, Interlock Protection, Emergency Stop |
|
Integration Options |
Conveyor, Robot, Vision System, MES |
Key Advantages
Unmatched Process Consistency: Digital energy delivery ensures uniform weld depth, hermetic seals, and clean visual appearance across millions of cycles.
Seamless Line Integration: Designed to plug directly into smart factory ecosystems (Vision inspection, MES, automated conveyors).
Flexible Product Changeover: Modular fixture plates and programmable PLC recipes allow fast switching between different product variants.
Class 1 Safety Standards: Fully enclosed protective cabin, safety light curtains, interlocking doors, and active laser safety windows protect operators completely.
Key Applications
1. Automotive & EV Manufacturing
EV Battery Assemblies: Battery housings, pack covers, cooling plates, module frames, and energy storage enclosures.
Automotive Components: Lightweight alloy structures, seat frames, battery trays, structural brackets, and exhaust systems.
2. Sheet Metal & Industrial Enclosures
Electrical & Control Systems: Electrical cabinets, control boxes, precision metal enclosures, and industrial covers.
Custom Metal Fabrication: High-precision chassis, frames, and sealed liquid/air containers.
3. Industrial Equipment Manufacturing
Precision Assemblies: Machine structural components, hydraulic valve manifolds, and high-pressure tubing.
Modular System Architecture
1. Fiber Laser Welding Unit
Laser Source Options: Premium tier based on budget and application.
Laser Head: High-precision wobble/galvo welding head with integrated air knife and protective cover glass.
Chiller Unit: Dual-circuit industrial water cooling system with intelligent temperature control.
2. Automated Material Handling System
Conveyor Systems: Heavy-duty roller or belt conveyors with stop-and-position modules.
Robotic Integration: 6-axis articulated robots for loading, unloading, and complex trajectory welding.
3. Precision Fixture & Positioning System
Quick-Change Tooling: Pneumatic/hydraulic custom fixtures with high-repeatability locator pins (<± 0.02 mm).
Anti-Deformation Clamping: Optimized holding pressure prevents part movement during high-speed thermal cycles.
Joint & Process Capabilities
Butt Welding: Precise edge-to-edge joining for sheet metals, pipes, and structural panels with tight fit-up.
Lap / Overlap Welding: Reliable deep-penetration joining for battery housings, pack covers, and layered metal assemblies.
Seam & Hermetic Welding: Continuous leak-proof sealing for cooling plates, liquid containers, and pressure-tight covers.
Wobble / Galvo Spot Welding: Programmable beam oscillation patterns to bridge wider gap tolerances and weld dissimilar materials (Copper to Aluminum).
Customization Options
Because no two production lines are identical, our systems are built modularly:
Product-Specific Customization: Fixture geometry, laser head focal length, shielding gas nozzles, and localized dust extraction.
Capacity Scaling: Add or swap modular conveyor lengths, dual-station shuttle tables, or multi-axis robots.
Factory Alignment: Tailored machine footprint, safety guard layout, and custom software interfaces matching your factory standards.
Pre-Shipment Validation
Every system undergoes rigorous Factory Acceptance Testing prior to delivery:
Sample Metallographic Test: Weld depth, penetration analysis, and tensile strength test.
Burn-in & Endurance Run: 48-hour continuous cycle testing to verify system stability.
Safety Interlock Audit: Full check of CE/Class 1 laser enclosure interlocks.
Global Service & Technical Support
On-Site Installation & Training: Overseas engineers available for setup, line commissioning, and staff training.
Rapid Spare Parts Supply: Critical modules (optics, nozzles, sensors) stocked for fast global dispatch.
Remote Diagnostics: Secure online connection for fast PLC/parameter troubleshooting.
Frequently Asked Questions
Q: What technical details do I need to provide for a system quotation?
A: To recommend the correct laser power and automation layout, we require:
CAD drawings (STEP/IGES) of the workpieces.
Material type, thickness, and joint configuration.
Target cycle time or required daily production volume.
Preferred automation level (Standalone cell vs. In-line conveyor).
Q: Can we perform weld testing on our sample parts before placing an order?
A: Yes. We encourage pre-order sample testing. You can send your sample parts to our application lab, where our engineers will test process parameters, evaluate weld cross-sections, and provide a comprehensive feasibility report.
Q: What factors influence the cost of an In-Line Laser Welding System?
A: Key cost drivers include selected fiber laser wattage (2kW vs. 6kW), the complexity of automated fixture tooling, robotic integration, vision seam tracking systems, and MES software customization.
Q: Is it possible to integrate this system into an existing assembly line?
A: Yes. Our system utilizes standard industrial communications protocols (Profinet, Ethernet/IP) and adjustable conveyor height modules, making it compatible with existing production equipment.
Q: Can the machine be expanded or upgraded in the future?
A: Yes. The system uses modular PLC control and standard mechanical interfaces. You can easily add vision inspection, upgrade laser power, or integrate robotic loading at a later stage as production demands increase.
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