FL-WELD-R

Laser Welding Cells

Robotic Laser Welding Systems

IPG’s Laser Welding Workcells comprise a world-leading fiber laser, a 6-axis robot and process heads in a Class 1 laser safety enclosure controlled by an industrial computer. The Workcell can be optimized for many different types of laser welding of a variety of parts made of carbon and stainless steel, aluminum, titanium, copper and alloys. Tailored to the specific needs of a customer, the Workcell can be equipped with options for laser cutting or cladding to maximize utilization of the fiber laser capabilities. With a modular design, the workcells offer a wide choice of laser powers, laser processing heads and motion system options. Specifications are typical capabilities; please contact IPG for a turnkey configuration optimized for specific applications.

3D

Features

IPG high efficiency fiber laser light source High strength of welded joints
IPG process head for optimum weld performance Processes without filler materials supported

Class-1 enclosure integrated with facilities interlocks

No interference on weld by magnetic fields

Modular and scalabe system Laser power from 1 to 30 kW for fast cycle time
Custom configurations to optimize investment dollars Static work table or 2-axes manipulator
Process and equipment designed and supported by IPG Work envelope from 1.2 to 2.7 m radius
Laser Power Options

Selectable at time of purchase:  CW 1 kW to 30 kW; Typ. 6 kW

Delivery Fiber Core Diameter, μm 

50, 100, 200

Beam Delivery Options

IPG Photonics’ FLW-D50 Welding Head
IPG Photonics’ FLC-D30 or D50 Cutting Head
Cladding Head- Application Dependent, Specify when Ordering
Beam Delivery Typically Includes:
Selectable Collimator/ Focus Lenses
Integrated Air-knife/ Cross-jet
Integrated Shield Gas Delivery Nozzle and Electronic Flow Control
Water-cooled Optics
Engineered cable management

Robot (Typical)

Selectable  at time of purchase.           6-axis:      1.81 m (72 in.) Reach:   up to 2.69 m (106 in.) Reach
Includes Robot Controller with Motion Package and Dual Safety Position and Speed Check
Work Envelope Radius:  1.8 m (72 in.) up to 2.69 m (106 in.)

Positioning repeatability, mm

± 0.06 typ.

Controls/ Interface

Stand-alone Mobile HMI Stand
Industrial PC with 17” Color Touchscreen
IPG Cell Control Interface
Front panel Controls for Emergency Stop, Laser Mode, System Reset, Cycle Start, Cycle Stop

System Integration

Electrical Integration of all Components; Software Integration of Robot, Laser, Cell Safety and
Beam Delivery

Tooling

Heavy Duty Table to Mount Customer Supported Tooling

Enclosure

Class 1 Laser Safety Enclosure
Dual Wall Aluminum Extrusion Panels
Laser Safe Viewing Window

Dimensions, m

 Workcell Enclosure dimensions range from 2.7 × 3.6 × 3.0 m up to 5.0 × 6.0 × 4.0 m

Optional Features

Beam Switching Beam Switching Module to Support Multiple Process Heads on a Single Laser
Automatic Tool Change Pneumatic Tool Change Coupler to Exchange between Welding, Cutting and Cladding Heads
CCTV Viewing Webcam Mounted Inside Workcell for Process Monitoring; Image Fed to HMI Screen

Part Motion System

2-axis manipulator 

Actuated Table Base

Additional Motion Axis to Move Table for Ergonomic Part Loading
Motor-driven with Locking Pins to Ensure Repeatability

  • IPG fiber laser
  • Laser cooling system
  • IPG optical welding head
  • Weld joint video guidance system
  • Industrial robot
  • 2-axis manipulator
  • Welding station control system
  • Protective enclosure equipped with welding fumes exhaust system and air cleaning system
Turnkey Robotic Laser Workcell DatasheetRobotic Laser Workcell Brochure

Applications

Processes

Seam welding Butt Welding
Spot welding Lap Welding
Deep penetration welding Welding with or without wire feed

 

Types of Materials 

Carbon and stainless steel
Alumimum and titanium
Highly reflective materials: copper and brass
Welding dissimilar materials

 

Industries

Automotive component manufacturing
Heavy engineering industry
Railway car-building industry
Shipbuilding industry
Aircraft industry
Power industry
Metal fabricators, machine shops

The Laser Welding Workcell can be equipped with additional options enhancing welding capabilities:

  • Welding power source, enabling simultaneous laser and MIG welding
  • Filler wire feed module, enabling laser welding with filler wire feeding
  • High-power and Mid-power Scanning modules, enabling remote laser welding
  • Wobble module: the Wobbler controllably broadens weld seams created with high quality high power focused beams while reducing required laser power. The Wobbler allows high quality welding even in the presence of some gap between the welded parts. The Wobbler improves welding process stability, repeatability and the weld seam aesthetics.
  • Seam Finder module: IPG Seam Finder is a modular adaptor for IPG FLW D30 and D50 Welding Head enabling welding seam tracking on fast moving parts. The Seam Finder is provided with IPG software and user interface in flexible configurations meeting specific user requirements. The user interface monitors the seam position allowing user to adjust welding head accordingly.
  • Wobble and Seam Finder Modules: providing simultaneous laser beam wobbling and weld seam tracking capabilities.
  • Dual-Spot Module: reduces spatter, increases welding speed, and improves weld quality and visual finish when the gap tolerance varies.

Fiber lasers enable reliable, easily controlled welding processes, and are completely maintenance-free. The welding equipment is located in the Class 1 enclosure which provides full personnel safety protection against laser reflected and scattered laser radiation. The welding process can be observed through laser-safe viewing windows, or using an optional vision system. The system is controlled through a PC housed in an IPG control rack.

  • Many types of welding including deep penetration welding
  • Possibility of welding without filler materials (cost savings)
  • Welding without prior edge beveling
  • No influence of magnetic fields of welded parts on the laser beam
  • Improved laser beam access to hard-to-reach places
  • Small volume of molten metal and small thermal exposure area
  • Minimal distortion of welded structures
  • High strength of welded joints
  • High speed joining of different metals regardless of their thickness (from a few micrometers to tens of millimeters)
  • Low energy consumption per running unit length of weld seam
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