Smart Laser Cobot Welding – robotic laser welding machine

Smart Laser Cobot Welding – next-generation laser welding automation

Smart Laser Cobot Welding is a complete workstation designed to automate laser welding processes in one-off, small-batch and series production. The combination of a precise 6-axis LEANTEC collaborative robot with a CW fibre laser achieves high process repeatability while maintaining great production flexibility.

The system can work with laser sources of 1500 W, 2000 W, 3000 W and 6000 W, so the workstation configuration can be tailored both to welding thin sheet and to much more demanding industrial parts. All source variants operate at a wavelength of 1080 nm, with power adjustment in the range of 10–100% and water cooling.

An industrial head instead of a handheld gun

One of the most important elements of the system is the dedicated industrial head for robotic laser welding. It is not an adaptation of a standard handheld welding head, but a solution designed for long-term automated operation.

The head features water cooling and an integrated beam oscillation module Wobble, which allows the weld to be widened and small part fit-up inaccuracies to be better compensated. Independent shielding gas control and a standard QBH interface are also available.

Automatic Push-Pull wire feeding

For processes requiring filler material, the workstation can work with a servo-driven wire feed system Push-Pull.

Two synchronised drives reduce problems typical of long wire feed paths, such as wire jamming, deformation or unstable feed speed. The system handles wires with diameters of:

0.8 / 1.0 / 1.2 / 1.6 mm

The feed speed can be adjusted in the range of 0–10 000 mm/min, and the controller synchronises it with the robot's movement speed and the laser parameters. Automatic wire retraction, a wire-out alarm and anti-jamming protection are also available. 

Programming by guiding the cobot

Smart Laser Cobot Welding has been designed to reduce the need for conventional robot programming.

The operator can manually guide the arm to successive process points, record the trajectory and then assign the appropriate welding parameters to it. The SYNTEC software offers dedicated commands for starting and ending welding, spot welding and laser power curve control.

The ability to store multiple parameter sets allows settings previously prepared for different materials and parts to be recalled quickly. The system also records part cycle time, the number of parts produced, process progress and current laser operating parameters.

Precision and repeatability

Depending on the cobot model selected, a working reach of 800 to 1300 mm, a payload of 5 to 15 kg and positioning repeatability of as little as ±0.02 mmare available. All models presented in the documentation have a protection rating of IP66.

As a result, the system performs well with both simple linear welds and more complex spatial trajectories.

Optional CCD weld monitoring

For the most demanding applications, the workstation can be equipped with a coaxial CCD camera located directly in the laser head.

The image of the weld pool and weld area can be observed on the controller screen in real time. The camera uses an industrial sensor designed to work in the intense light of the process and in the presence of spatter.

The solution is particularly interesting in the production of parts requiring increased process control, including automotive components, battery housings, medical devices and precision stainless steel structures.

Wide range of applications

Smart Laser Cobot Welding can produce, among other things:

• butt welds,
• fillet welds,
• lap joints,
• multi-layer welding,
• closed circumferential welds,
• stitch welding,
• welding in various spatial positions.

The system is used, among other things, in the production of steel structures, agricultural machinery, automotive parts, stainless steel equipment, aluminium structures, transport equipment and metal fabrication.