“The Art of Scanner Welding” – Expanded

Laser welding cell with Scanlab/Blackbird scanner in teach mode (Source: B&S)

Laser welding cell with Scanlab/Blackbird scanner in teach mode (Source: B&S)

With over 15 years of experience in remote laser processing, Bergmann & Steffen has established itself in the market as a developer and supplier of “turnkey” laser welding systems and clamping tools for the automotive industry. Complex system solutions are developed, manufactured and installed on production sites all over Europe.

Earlier this year, the company made the decision to expand the laser center, which has been in operation since 2011, with the latest system technology available. For years the laser center has offered training, applications, sample production and prototyping as well as small batch production.

The laser centre currently has two cells with active laser protection walls, each equipped with one ABB industrial robot with different positioners for aligning laser optics. Recently, the “light supply” of the laser optics is supplied by a Trumpf TruDisk 6001. This disk laser has a maximum output of 6 kW at the workpiece and a two-way beam splitter for connecting laser light cables with a diameter of ≥ 100 µm, to guide the beam to one of the two cells.

One cell will be equipped with the existing, tried and tested Scanlab/Blackbird scan head. The technological highlight of this system is a unique camera-based inline seam-tracking system which allows accurate laser welding of so-called throat fillet welds.

Laser cell with Intelliweld 30FC-V laser optics by Scanlab, online weld seam tracking system “Weldeye”, and Bergmann & Steffen crossjet blower “Tornadoblade” (Source: B&S)

Laser cell with Intelliweld 30FC-V laser optics by Scanlab, online weld seam tracking system Weldeye, and Bergmann & Steffen crossjet blower Tornadoblade (Source: B&S)

Laser welding cell with new iPFO laser optics by Trumpf and new Bergmann & Steffen crossjet blower “Tornadoblade” (Source: B&S)

Laser welding cell with new iPFO laser optics by Trumpf and new Bergmann & Steffen crossjet blower Tornadoblade (Source: B&S)

The new Trumpf I-PFO programmable focusing optics is adapted on the robot in the largest cell, which is equipped for larger assemblies such as body modules, doors, lids and complete car bodies.

The intelligent PFO (I-PFO) is the latest generation of programmable focussing optics PFO which have been successfully used in the car industry for many years. The I-PFO knows its own position in the working area of the robot as well as the location and orientation of the processing points, e.g. weld seams on the workpiece. On the basis of information on the current robot movement, which it continuously receives, the I-PFO begins processing autonomously wherever geometry and process technology make it possible to do so.

By the end of this year, Bergmann & Steffen will be one of the first companies to be able to present the Trumpf TruDisk 6001 and the new I-PFO combined with an ABB IRB 6640 live in operation.

Links: Laser Application Center, Bergmann & Steffen GmbH, Spenge, Germany

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