Presentation SOUTRAC Non-Linear Weld System/media/Files/Autosteel/Great Designs in Steel... · Presentation SOUTRAC ... movement (x,y), we need 5 numerically controlled axes integrated

w w w . a u t o s t e e l . o r g

Presentation SOUTRACPresentation SOUTRAC®®

NonNon--Linear Weld SystemLinear Weld System

SOUTRAC SOUTRAC -- The Future for Welding The Future for Welding AHSS Tailored BlanksAHSS Tailored Blanks

Soudronic AutomotiveSoudronic Automotive


SOUTRACSOUTRAC®®

Characteristic of PartsCharacteristic of Parts

Linear

Linear shifted

Non linear


0

10

20

30

40

50

60

70

Rai

ls 2

002

Rai

ls 2

005

Pilla

rs 2

002

Pilla

rs 2

005

Tunn

el/W

heel

h.Tu

nnel

/Whe

elh.

Oth

ers

2002

Oth

ers

2005

Clo

sure

s 20

02C

losu

res

2005

Bod

y S

ide

/B

ody

Sid

e /

Volu

me

in M

io. T

B

non linearlinear

Application oriented

0

50

100

150

200

250

2000 2005

Market volume total

SOUTRACSOUTRAC®®

Market Share NonMarket Share Non--linear Tailored Blanklinear Tailored Blank


SOUTRACSOUTRAC®®

TheThe SolutionSolution


SOUTRACSOUTRAC®®


y-axis

max. speed: 30 m/minmax. acceleration: 4 m/s2

x-axis

max. speed: 120 m/minmax. acceleration: 4 m/s2

weld speed: 2...18 m/minmin. radius: 100 mm

max. blank size: 2200 x 3600 mmmax. # of blanks: 4max. # of welds: 12


SOUKA®

Mechanical gap closing

Gap bridging Edge tracking Weld process Quality control

Func

tion

grou

ps

SOU

TRA

C®

SOUVIS® 1Edge position measurement

Laser head• Monobloc• Process gas• Laser position

control

SOUVIS® 2Seam profile topSeam profile root

SOUVIS® 3Seam homogeneity

SOUVIS® 1 (SOUVIS® 5000)• Edge position

measurement• Gap determination

Laser head• Monobloc• Process gas• Laser position control• Gap driven filler wire• Double spot

SOUVIS® 2(SOUVIS® 5000)• Seam profile

top• Seam

homogeneity

SOUTRAC® combines all functions in only 3 groups

SOUTRACSOUTRAC®®



SOUTRACSOUTRAC®®

TheThe Solution Solution -- Absolute Absolute AccuracyAccuracy of of MainMain AxesAxes

R =

100

mm

0.1 mm

x-axis, weld shuttle

y-ax

is, w

eld

head

V = 12 m/min

Measured position

Nominal position

Nominal weight of weld shuttle 4000 kg

Nominal weight of weld head 300 kg

Maximum absolute deviation 0.05 mm


Main axis y

Main axis x

SOUVIS® 2 SOUVIS® 1

Laser head

Rotation axislaser head

Swivel axisSOUVIS® 1

Weld line

Rotation axisSOUVIS® 1

Swivel axisSOUVIS® 2

Rotation axisSOUVIS® 2

Requirement for quality welds:Following precisely a curved contour with 3 different function groups each positioned normal to the weld line

Solution:Besides 2 main axes for the main movement (x,y), we need 5 numerically controlled axes integrated into the weld head

SOUTRACSOUTRAC®®

The Solution The Solution -- FollowingFollowing a nona non--linear linear weldweld line...line...


SOUTRACSOUTRAC®®

FollowingFollowing a nona non--linear linear weldweld line... line... (cont.)(cont.)

Requirement for quality welds:Welding different blank gauges in the same weld cycle, even T-shaped combinations can occur.

Solution:Each function group has its own independent numerically controlled height (z-) axis. Weld line

SOUVIS® 2SOUVIS® 1

Laser head


Actual edge position

Requirement for quality welds:Following precisely a curved contour even if the pre-programmed line does not fit with the actual edge position

Solution:Position dependent edge tracking and position-driven correction of the laser head normal to the actual weld line

Pre-programmed edge position

Image size SOUVIS®

1+2: 10 x10 mm

SOUVIS® 1 edge tracking

Deviation calculation at actual position

CNC: Ring buffer for correction numbers and position-driven laser axis correction

Laser head with correction axis normal to weld line

SOUTRACSOUTRAC®®

Following a nonFollowing a non--linear weld line... (cont.)linear weld line... (cont.)


SOUTRACSOUTRAC®®

Varying Gaps....Varying Gaps....

Requirement for quality welds:Overcome varying gap width up to 0.3 mm

Solution:Position dependent gap width measurement and corresponding control of wire feeding speed

Position dependent gap

SOUVIS® 1 gap determination

Laser head with filler wire capability

Gap width at actual position

CNC: Ring buffer for gap width and control of position-driven filler wire speed

Wire feeder


SOUTRACSOUTRAC®®

Mechanical solution for the weld headMechanical solution for the weld head

Laser light cable

Rotation axis laser head

Gap driven filler wire

Swivel axisSOUVIS 2

Swivel axisSOUVIS 1

(Patent pending)(Patent pending)


SOUTRACSOUTRAC®®

Welding DemonstrationWelding Demonstration


SOUTRACSOUTRAC®®

Gap Issue in NonGap Issue in Non--Linear Welding ApplicationsLinear Welding Applications

There is a higher risk of the gap problem in the non-linear Tailored Blanks welding process due to the sum of geometrical tolerances.

Therefore a safe solution for the gap closing prior to welding pTherefore a safe solution for the gap closing prior to welding process is rocess is mandatory.mandatory.

Only then a safe and reliable high production output can be guaranteed!


Gap = Missing materialGap = Missing materialPossible causes of gap:Possible causes of gap:

Released tension during blankingReleased tension during blankingTolerance of part measurement and/or positioningTolerance of part measurement and/or positioningLarge die gapLarge die gapDamage during transportation/handlingDamage during transportation/handling……………………………………

SOUTRACSOUTRAC®®

What is a Gap?What is a Gap?


Blanking is a Forming Process:Good formability of mild steel means good blanking ability

Limited formability of AHSS means bad blanking ability

Shear to break ratio and material deficit

Mild SteelSame shear gap

AHSS

SOUTRACSOUTRAC®®

Steel Formability Effects on Edge QualitySteel Formability Effects on Edge Quality


Filler wire speed (m/min.) Gap width (mm)

SOUTRACSOUTRAC®® Solution Solution Automatic Adjustment of Filler Wire SpeedAutomatic Adjustment of Filler Wire Speed


Position (mm) Gap width (mm)

SOUTRACSOUTRAC®® Solution Solution Automatic Adjustment of Laser PositionAutomatic Adjustment of Laser Position


Gap 0.38 mm Corresponding weld withcontrolled filler wire

SOUTRACSOUTRAC®® Solution Solution The End ResultThe End Result


G / DOCOL 1400

0

100

200

300

400

500

600

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2

Här

te H

V1

A / TRIP 600

0

50

100

150

200

250

300

350

400

450

500

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2

[ mm]0 1 2

Distance from seam centre [mm]

0 1 2

Distance from seam centre [mm]

Har

dnes

s H

V1

0

5 00

Har

dnes

s H

V1

0

600

G / DP 1400

SOUTRACSOUTRAC®® Solution Solution Examples of Hardness ProfilesExamples of Hardness Profiles


SOUVIS® 1Edge position determinationGap width determination

SOUVIS® 2Profile analysis

Seam homogeneity analysis

Laser headIntegrated position control axis Gap driven filler wire

SOUTRACSOUTRAC®®

Integration of SOUVISIntegration of SOUVIS®® 5000 Inline Quality System5000 Inline Quality System


CMOS Camera with adaptive response characteristics

Diode laser line

Combined acquisition of gray scale image and

laser triangulation line

10 mm10 m

m

Resolution 0.01 mmMax. speed 30 m/minMax. data flow 60 MB/s

Short pulse flash light

SOUVISSOUVIS®® 5000 5000 Sensor PrincipleSensor Principle

(Patent pending)(Patent pending)


Extraction of seam geometry information

Extraction of seam homogeneity information

Easy to operate,Low number of parameters

Reduced maintenance andspare parts requirements

Easy to integrate

No complicated and diffuse fuzzy logic necessary to combine multiple sensor arrangements

Microscopic resolution and outstandingdiscrimination capabilities (human eye is the standard)

SOUVISSOUVIS®® 5000 5000 One Sensor for all RequirementsOne Sensor for all Requirements


Determination of • Edge position (laser position

control)• Gap width (wire feeding control)• Blank gauge difference• Blank alignment• Edge quality

SOUVISSOUVIS®® 5000 5000 SOUVISSOUVIS®® 1 Edge Tracking1 Edge Tracking


Determination of• Seam concavity• Seam convexity• Mismatch• Seam width• Seam roundness• Lack of penetration• Porosity• Expulsion• Pinholes

SOUVISSOUVIS®® 5000 5000 SOUVISSOUVIS®® 2 Quality Control2 Quality Control


Upper seam surface of a

tailored blank

Texture analysis

Profile analysis

Pore analysis

SOUVISSOUVIS®® 2 2 Image AnalysisImage Analysis


Local edge defects

Plasma absorption

Reasons for Failure

Expulsions, holesMissing texture

SOUVISSOUVIS®® 2 2 Gray Scale Image AnalysisGray Scale Image Analysis


Porosity

Reason for failurePartial evaporation of dirt or zinc particles located between the weld edges

0.1 mm x 0.3 mm

SOUVISSOUVIS®® 2 2 Gray Scale Image AnalysisGray Scale Image Analysis


A safe online quality control is a must for an efficient production of non-linear tailored blanks.

Its not sufficient to detect some of the relevant weld failures and some not.

SOUVIS® 5000 represents the only integrated solution today capable of detecting all relevant failures in non-linear tailored blanks.

SOUVIS® 5000 performs with only one unique sensor, i.e. less complexity and more reliability.

SOUVISSOUVIS®® 50005000SummarySummary


Golf Door (non linear)

Cycle Time: 10.5sec / TB

5

SOUTRACSOUTRAC®®

Example PartExample Part


Cycle Time: 36sec / TB

GMT 370 Body Side

6

SOUTRACSOUTRAC®®



Cycle Time: 25sec / TB

A-MPV (PQ35)

7

SOUTRACSOUTRAC®®



Cycle Time: 16.0 sec / TB

1346

1288

Honda New Accord Front Door Upper

8

SOUTRACSOUTRAC®®



ROVER 75 Front Door)

Cycle Time: 12.5sec / TB

9

SOUTRACSOUTRAC®®



Cycle time per side ring 25 sec.Cycle time per side ring 25 sec.

PP-F1Produktionstechnik Marke Volkswagen

Schulz-Marner Stand: 11.00 (K:\...\A_MPV_SLW\Bilder\St_innen_Neues_Konzept\A_MPV_ST_i_2_tei_2l)

Tailored Blanks Platinen

A-MPV Seitenteil Innen 4teilige Platine

ZStE220 Z 100 MB 1,0mm alternativ: ZStE220i Z 100 MB 1,0mm

ZStE260 Z 100 MB 1,2mm

2000

mm

550m

m

2600mm

ZStE260 Z 100 MB 1,0mm

ZStE220 Z100 MB 1,5mm alternativ: ZStE220i Z 100 MB 1,5mm

Wal

zric

htun

g

Walzrichtung

Walzrichtung

Walzrichtung

SOUTRACSOUTRAC®®

Production System for Body SideProduction System for Body Side


Cycle time

15.8 sec

16.3 sec

17.0 sec

SOUTRACSOUTRAC®®

ProductionProduction System forSystem for Body SideBody Side


SOUTRACSOUTRAC®®

ProductionProduction System forSystem for Body SideBody Side


SOUTRACSOUTRAC®®

LayoutLayout


SOUTRACSOUTRAC®®

SummarySummary

SoudronicSoudronic SOUTRACSOUTRAC®®

The right solution to meet the high The right solution to meet the high market demand !market demand !

regardingregarding-- high output of quality Tailored Blankshigh output of quality Tailored Blanks-- low scrap ratelow scrap rate-- high uptimehigh uptime

based onbased on-- 20 years of experience20 years of experience-- 38 Mash Seam TB welding lines38 Mash Seam TB welding lines-- 5454 Laser Seam TB welding lines Laser Seam TB welding lines (11(11-- 02)02)

Documents

Presentation SOUTRAC Non-Linear Weld System/media/Files/Autosteel/Great Designs in Steel... · Presentation SOUTRAC ... movement (x,y), we need 5 numerically controlled axes integrated