Robotic systems for laser welding

Robotic Laser Welding

The robotic laser welding system is a technological complex where the main working components are an anthropomorphic 6-axis robot that manipulates the laser head and a laser radiation source. The laser beam is generated by the source and transmitted through an optical fiber to the laser head. The head focuses the laser beam onto the workpiece, while the robot ensures the precise movement trajectory required for welding.

Continuous welding is performed using fiber lasers, typically with a wavelength of 1.07 μm, capable of delivering power from hundreds of watts up to tens of kilowatts.

The speed of continuous laser welding is several times higher than that of traditional fusion welding methods. At the same time, it provides excellent weld quality, as demonstrated by the test results shown below.

Table. TIG and Laser Welding Modes

Cross-section macrographs of welds:
(a) TIG weld;
(b) Laser weld.

Deformation pattern in welds performed by TIG (a) and laser (b)

Recently, robotic laser welding systems have become increasingly widespread. This is due to the advantages of the process over traditional welding methods:

• capability to weld a wide range of metal grades;
• high welding speed (0.3 – 40 m/min);
• minimal heat-affected zone;
• ability to weld in a single pass without edge preparation (penetration precision);
• high weld quality. Robot repeatability – 0.02 mm;
• consistent quality (robot repeatability – 0.02 mm).

LLC "Intellectual Robot Systems" has been operating in the complex technological equipment market for over 10 years. Our systems integrate laser technologies from renowned brands such as Coherent and IPG (IRE-Polus).

Coherent was founded in 1966 and is currently one of the world’s leading manufacturers and innovators in photonics. An innovative solution in laser systems developed by Coherent is the dynamic ring mode of laser emission. This allows for precise energy distribution between the rings of the laser beam, as shown in the image below.

Energy level adjustment of the central and outer ring

LLC NTO "IRE-Polus" is one of the key companies of the IPG Photonics Corporation scientific and technical group. Their manufacturing facilities and research centers are located worldwide, including Russia, the USA, Germany, and Italy. This company produces 25% of all lasers globally.

The basic universal solution for robotic laser welding looks like this:

Specification of the Basic Universal Solution for Robotic Laser Welding

The composition of a robotic laser welding system can vary depending on the customer's requirements and may additionally include:

1. Robot mounting systems: linear guides, columns, gantries, etc.;
2. Observation and machine vision systems;
3. Welding manipulators, positioners, roller supports, etc.;
4. Technological tooling;
5. Tooling change system;
6. Offline programming system;
7. Other components necessary to perform technological functions.

As an example of an implemented project, a robotic laser welding complex for the "FGUP PSZ Trekhgorny" plant can be cited. Photos from the project are shown below.