Robotic laser welding system for ladder trays
The robotic system is designed for welding stainless steel ladder trays using laser welding technology, both with and without filler material, in an inert gas environment.
The system allows welding large quantities of various sizes while eliminating human error, maximizing productivity, and reducing post-weld processing time compared to other technologies.
The complex features a 3-axis carousel-type positioner, which minimizes equipment downtime during continuous cycles and reduces setup time for different sizes of products.
Application: Special, civil
Material: Structural, heat-resistant, and stainless steels
Welding type: Laser welding with filler material
Overview of the System
System Components:
- Industrial manipulator
- Wire feeding mechanism
- Laser optical head with integrated beam deflection system along a defined trajectory
- 3-axis carousel-type positioner
- Laser power source
- Liquid cooling system
- Workpiece conductor
- Protective light barriers
- Protective chamber
Additional equipment not shown:
- Filter-ventilation system
- Inert gas monoblock
The system operates in three shifts.
The welding cycle of a tray includes the following steps:
- The operator manually installs and secures the semi-finished parts in the conductor mounted on the 3-axis rotary positioner.
- The operator selects the welding program and presses the start button.
- The positioner moves the conductor with the installed semi-finished parts into the welding zone and initiates the robotic laser welding process.
- The second conductor is presented to the operator to remove the finished part and load new semi-finished parts.
The conductor contains brass inserts for passive cooling during welding. Robot movements between welds are performed along a rail track.
System Components
Industrial Robotic Manipulator
Mechanism type — 6-axis robot
Maximum payload — 36.6 kg
Maximum working radius — 2100 mm
Position repeatability (ISO9283) — 0.05 mm
Axis rotation 1/2/3/4/5/6 — 370/235/285/360/250/700°
Maximum axis speed 1/2/3/4/5/6 — 180/165/180/250/250/360°/s
Laser Optical Head
Dimensions (L×W×H) — 178×137×375 mm
Weight — 5.4 kg
Maximum power — up to 6 kW
Focal length — 400 mm
Spot diameter at focal length — 0.533 mm
Maximum water cooling pressure — 5.0 bar
Laser Power Source
Laser type — Ytterbium fiber laser
Central wavelength — 1070˚±5 nm
Modulation frequency — 0–5 kHz
Maximum average power — 3 kW
Operational power stability — 10–100%
Deviation from nominal power — ±2%
Workpiece in Special Fixture
Cooling System and Laser Power Source
Filter-Ventilation System
Examples of Completed Welds
Gallery of completed projects
