Applications and Advantages of Robotic Laser Welding in Modern Manufacturing

Robot laser welding machine have successfully entered the forefront of the manufacturing industry and can replace manual welding. Laser welding has also accumulated many years of experience in the field of non-contact welding. Robot laser welding makes high-speed processing and low heat input possible with extremely high energy density, high welding strength, narrow weld seam, small heat-affected zone, and small deformation of the workpiece. With ever-changing user needs and widespread use in various industries, robotic laser welding has become the general trend of the future.

For users, finer segmentation of product lines will become the new normal. This will reduce the need to mass-produce the same parts, and the preparation time for each product is increasing, and the entire processing process, especially the welding process, must adapt to this trend. The most suitable equipment to meet this demand is the six-axis robotic laser welding system.

What is a robot laser welding machine?

A robot laser welding machine is an advanced automated and intelligent device that combines robot technology with laser welding technology to execute welding tasks. It typically consists of a multi-axis robot system and a laser source. Through precise control and programming, it achieves highly accurate welding processes. Robot welding machines can flexibly perform welding on workpieces from various angles and positions, even in confined or intricate areas, reducing the need for manual intervention and operation. Robot laser welding machines utilize laser as the heat source, harnessing its high energy density to focus a laser beam onto the junction of two material parts. This induces rapid localized heating and melting. Subsequently, upon cooling and solidification, the two material parts tightly bond, forming a seamless welded connection.

Characteristics of Robot Laser Welding

1. Labor Savings: Employing an L-shaped configuration with material loading on the left and welding on the right, the robot operates continuously. Welding robots equipped with auxiliary devices can automate the flipping of thick plate weldments and facilitate repetitive production, liberating workers from demanding welding tasks.
2. Enhanced Production Efficiency: Replacing traditional welding methods, robot laser welding reduces the need for polishing and achieves speeds 2 to 5 times faster.
3. Consistent Welding Quality and Increased Product Yield: Prior to welding different workpieces, the robot automatically identifies welding seams and applies welding material to fill gaps. This results in visually appealing, robust welds and heightened product uniformity, thus elevating the rate of qualified products.
4. Flexibility in Six-Axis Welding: With six axes, robots can achieve greater flexibility and accommodate various angles for welding applications, such as in tube-type motorcycles and furniture.
5. Improved Collaborative Operation: For larger products, two robots can collaborate simultaneously, further enhancing welding efficiency.
6. Cost Savings for Precision Products: Robot laser welding is particularly economical for seamlessly joining or welding small gaps in sheet metal components. Additionally, it eliminates the need for wire feeding, reducing welding wire costs.

Applications of Laser Robot

The demand for robots is particularly high in key industries such as machinery, automotive, electronics, petrochemicals, light industry, textiles, metallurgy, construction materials, food, and pharmaceuticals. Robot laser welding technology boasts extensive versatility, especially for mass production of materials like stainless steel, carbon steel, aluminum alloys, and galvanized sheets within a thickness range of 0.6-5mm. The main application areas span across multiple industries, including equipment enclosures, hardware furniture and lighting, railing doors and windows, new energy industries, and electromechanical products.

1. Automotive Industry: The application of robot laser welding in the automotive manufacturing sector has propelled the development of laser processing into an era of large-scale usage. As per relevant data, 50%-70% of automotive components require laser processing, and with the continuous expansion of the automotive industry, there is a significant demand for robot laser processing. Notably, the welding application for power battery packs in new energy vehicles alone has generated substantial equipment demands for the laser industry.
2. Electronics Industry: The electronics sector demands high welding quality. With the continuous rise in demand for electronic devices, rapid growth in the electronics industry is accompanied by formidable challenges. Robot welding equipment ensures stable welding quality while maintaining production efficiency, achieving precise welding of electronic devices, and increasing efficiency three to four times compared to manual methods.
3. Shipbuilding: Ship structures consist of nearly a thousand welded components involving tens of thousands of parts. Vital load-bearing components of ships predominantly use welded structures, facing strict welding requirements due to the substantial pressure endured during vessel operation. Robot welding equipment employs automatic seam tracking technology to flexibly adjust welding parameters, accurately welding various parts of ships.
4. New Energy Sector: Robot laser welding realizes efficient connections for solar panels, enhancing the energy conversion efficiency of photovoltaic devices and contributing to the promotion of green energy.
5. Hardware, Furniture, and Lighting Industry: In this sector, robot laser welding efficiently accomplishes precise welding of intricate components, ensuring structural stability and superb decorative effects, thereby enhancing the quality and aesthetics of furniture and lighting products.
6. Railing Doors and Windows: In the manufacturing process of railing doors and windows, robot laser welding technology not only accelerates welding speed but also ensures the robustness of welds, guaranteeing the safety and durability of railing doors and windows.

In the realm of metal welding, several challenges have emerged. Workpiece shapes are becoming increasingly intricate, demanding higher welding quality. Moreover, the rise of personalized orders with small batch sizes adds complexity. Robot laser welding systems are ideally equipped to address these challenges. Laser welding has been applied across industrial sectors for many years, and recent advancements in control and laser technologies have simplified its utilization, fostering its development. Furthermore, an increasing number of laser welding systems now integrate offline programming software and weld seam detection sensors, reducing preparation time and enhancing work efficiency.

Robot laser welding leverages its numerous advantages such as high precision, speed, minimized heat-affected zones, and automation. It stands at the forefront of welding technology innovation, ushering in more efficient, precise, and reliable welding solutions for the manufacturing industry. Whether in enhancing product quality, production efficiency, or expanding application domains, robot laser welding holds immense potential.