Spot Weld Carbon Steel
Pulsed nd:YAG – Stainless Steel Seam Weld Joint
Pulsed nd:YAG Laser Seam Weld Aluminum Membrane
Pulsed nd:YAG Laser Seam Weld Copper Membrane
Pulsed nd:YAG Laser Seam Weld Brass
to Stainless Steel
Laser Seam Weld Copper to Gold
AUTOMATED CELL PHONE PRODUCTION SYSTEM
LASER SPOT WELDING & MACHINE VISION INSPECTION
2 UP TOOLING – 2 SECOND CYCLE TIME PER UNIT
DESIGN LAYOUT, LASER WELDING SYSTEM –
Cell Phone Frame/Vibration Clip production rate of 2 units every 4 seconds.
Six (6) Station rotary Index System (Two Up Tooling): 1 Load Frame, 2. Load vibration Clips,
3. Laser Spot Weld, 4. Machine Vision Inspect, 5. Reject Station, 6. Unload Welded Assembly.
Second Phase of project replaced operators with one Pick n Place robot, from and into trays.
Photo – Automated Cell phone welding and machine vision inspection system
INTEGRATED LASER WELDING SYSTEM FEATURES (Class 1 safe operation system):
- The Laser Station includes a pulsed nd:YAG laser with two fiber optic cables each with a weld head delivering 25 joules of pulsed laser energy for the time share sequential welding of the two Piston Assembly weld joints; 1. Four (4) Spot Welds each 900 apart (Disk OD to Piston ID), 2. Seam weld Pin around bottom in bottom of Piston. Total Cycle time including automated loading and unloading to and from the welding fixture is < 30 seconds per Piston Assembly.
- The system design includes an automated system to sequentially rotate the Piston Assembly for the sequential welding of both weld joints. The two fiber optic delivered laser beam weld heads are mounted in a fixed postion on opposing sides (1800) of the rotating Piston Assembly. The rotary indexer is a servo driven rotary fixture with self-centering clamps to vertically hold the Piston Assembly in line with the laser beams. .A programmable optical beam diverter sequentially couples the laser beam into each fiber weld head positioned for each weld joint.
- A Class 1 laser safe enclosure shields the operator from any laser radiation. The piston conveyor is an asynchronous indexing unit with pallatized fixtures that singulate each Piston Assembly, and holds the Piston Assembly in a fixed upright postion. The Laser Welding Station has an automated pick and place unit to pick n place each pistion into the rotary fixture. A parts presence sensor trigers the laser weld cycle. After completion of the weld cycle, the a pinc n place unit unloads the Piston Assembly onto an output conveyor.
- A PLC was programmed to interface with the Laser for control of the complete systems cycle.
AUTOMATED LASER WELDING-MARKING, INSPECT (weld), & TEST SYSTEM – Layout Diagram:
Seam weld of a battery pack for a pacemaker
Eight (8) Station automated Synchronous Rotary Index system. Stations: – #1 Auto Load, #2 Vacant, #3 Hi Pot, #4 Laser Weld & Inspect, #5 Hi Pot, #6 Laser Mark, #7 Unload, #8 Vacant
Precision spot welding of micro gears
Seam Weld SS Tube
Circular seam weld of sapphire inlets
Helium-tight seam welding of a hybrid casing
Circular seam-welding of a sensor casing
LASER WELDED PRECISION MACHINED BIOMEDICAL ASSY – 4 step progressive process (Laser Welded assembly is subsequently Helium Leak tested to 10-8 CC)
1. Assemble Stem to Cap & Hermetic Seam Weld – (Both 304 SS)
2. Assemble Threaded Yoke to Cap/Stem Assy (Step 1) &Stitch Weld Yoke to Cap/Stem Assy
3. Assemble Bellows (316) to Cap (304) & Hermetic Seam Weld
4. Assemble Bellows (316) to Flange (304) & Hermetic Seam Weld
Manual Parts Loading, Automated Welding (10 sec cycle time)