Scanonic has demonstrated a new laser-welded FCW processing system at the 2023 Optoelectronics Show in Munich, Germany. The system combines multiple scanner units, making it possible to handle large components, or multiple components simultaneously.
In the future, Scanonic will offer its customers an entirely new way to achieve cost-effective parallelization of laser processes for particularly high welding speeds: FCW(Rapid Component Welding) system technology.
With this new technology, an extremely compact scanner unit can be properly integrated on a single process-specific application board. This means that it can process multiple components simultaneously, resulting in a higher output in the same amount of time.
In addition, the system's extended scanning field allows it to process larger components in one step. The scanning units can be controlled individually or in concert. This enables independent process control strategies at the same time as high quality.
Faster speed, better quality
This new system is the best example of Scansononic's continuous improvement in the speed and quality of laser processing.
Alongside global efforts to reduce emissions, there is a growing demand for efficient fuel cells, batteries, electric motors, high-performance electronics, and cooling technologies. This also requires new laser processing technologies, such as laser welding for bipolar plates, battery contacts, hairpins or surface coolers for automotive battery trays in electric vehicle drives.
At the same time, the industry's requirements for welding speed are also high. For example, a single bipolar plate requires a total length of weld up to 4.5 meters for a cooler plate, this distance can reach 100 meters. An electric motor consisting of up to 400 hairpins or a battery tray with up to 1,000 anode and cathode welds requires up to 2,000 welds. Joints must also be of a high standard. Most parts and each seam must be helium-dense. If a single seam fails, the entire assembly needs to be scrapped. This is why users expect the highest quality in terms of electrical, mechanical and structural component performance.
Improve production efficiency with FCW technology
Scanner units equipped with Scansononic's new FCW technology can be combined into multiple units, either in series or as a matrix. As a result, they offer a large scanning field, fast mirror motion, a powerful Z shifter for workpiece height compensation, automatic image recognition, and complex quality monitoring.
In the case of bipolar plates and surface coolers for car battery trays, this layout means that the speed of effective welding is significantly increased because multiple joints can be welded simultaneously. The scanning unit can be set to 90° when welding the Hairpin. Each unit can approach a segment on the stator, illuminate it evenly, detect its position and weld it out. This means that the stator no longer needs to be turned, regardless of its size. Rotating the stator is not only costly, but also a factor in determining process productivity.
With FCW system technology, Scanonic offers plant and mechanical engineers standardized and pre-tuned laser welding systems that simplify automation and personalized adjustments in the field while shortening workflows.
Source: OFweek
