4Hybrid Robotic Welding-Synergic Adaptive Evolution

8/3/2019 4Hybrid Robotic Welding-Synergic Adaptive Evolution

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Overcoming Obstacles w ith Hybrid

Robotic Welding The Evolution ofSynergic and Adaptive Welding

AWS/ NRAWC&EMilwaukee, WI

05/ 23-25/ 2011

Paul DenneySenior Laser Applications Engineer

[email protected]


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Overcoming Obstacles w ith Hybrid Robotic WeldingOvercoming Obstacles w ith Hybrid Robotic Welding

Presentation Outline Drivers and challenges

Changes in power supplies and robots Changes in lasers

Hybrid processing

- What is it?

- How is it being used? New potential for integrated systems

Summary and conclusions


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Presentation Outline

Drivers and challenges

Changes in power supplies and robots

Changes in lasers

Hybrid processing

-

What is it?- How is it being used?

New potential for integrated systems



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Dr ive rs :

Produc t i v i t y

- Com pe t i ng i n t he w o r l d

- Low er labo r con ten t

I m p r o ved q u al i t y Flex ib i l i t y

G reen


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Dr i v i n g Fo r ce- Au t o m a t i on and Produ c t i v i t y

Deve loped Coun t r ies vs Deve lop ing Coun t r ies Labor

Rates- Manufac tu r ing Labor Rate

Com pa r i son ; US 100% ; Ch i n a 4 .2 % ; I n d i a 3 .1 %

- Ch i n a h as g on e f r o m 2 .4 % t o 4 .2 % f r om 2 0 0 5 t o 2 0 0 8

M ate r i a l s and Equ ipm en t a re Globa l Com m od i t ies

US im p rovem en ts i n Pr o d u c t i v i t y ( 8 7 - 0 9 )

For d eve loped coun t r ies t o co m p e t e i n w o r l d m a r k e t

t h e n t h e am o u n t o f l a b or i n m anu factu red goods has t o be decreased.


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Chal lenges: High er p r ocess ing

r a t es W eld seam s

- F i t -up

- F ix tu r i ng

Mater ia l s - Comb ina t i ons

- Th inner

- H ig h e r s t r e n g t h

Advan ced design s


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Changes in lasers

Hybrid processing

-

What is it?- How is it being used?




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Arc We ld ing Pow er Supp l i es

S ta t i c - Des igned a r ound user

feedback and con t r o l - Sim p le in design

- I ssu e s w i t h i n t e g r a t i on i n t o r obo t i c system s

Dig i t a l pow e r supp l i es - Sta t e based con t ro l

Mo n i t o r i n g b u i l t i n Se lect ion o f t he w e ld ing

m ode as w e l l as howchanges shou ld occur

- Ce n t r a li ze d c on t r o l ; Po w e r su p p ly -Ro b o t con t r o l

Can con t ro l pow er supp ly ,w i r e f e e d, a n d ro b o t

ACC-255S

I400 Power Supply


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Ear ly Robot s an d Laser s

Accuracy

- Po in t - t o -po in t - D y n a m i c

I n t e g r at i o n t o l ase r t y p e

- CO2

Requ i red h a rd op t i cs

- Fibe r d e l ive ry no t ava i lab le

- No h igh pow er CW

Nd:YAGs GMF -100 First Laser Robot Integral CO2 Beam Circa 1988

Cincinnati Milacron T3


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Laser W or k Cel ls vs Robo ts

Spec ial i zed w or k cel l s - Accura te

- High cost

- Lim i t ed f l ex i b i l i t y

A r t i cu l at e d ar m + r o b o t

- Use o f st anda rd r o b o t

- Flex ib le

- A li g n m e n t a n d

m o v em e n t i ssu e s

Laser Mech Arm For CO2 laser Coupled to robot


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Hybrid processing

- What is it?




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Historical Laser Systems

Low to High Power CO2- Early 80s to present

- 100 W to 24 kW

- Hard optics delivery

- Welding and cutting

- Slow response time

- Lower initial cost but lowefficiency (5% to 13%)

CW Nd:YAG- Mid90s to Mid00s

- 4 kW max

- Fiber delivery

- 3D cutting and welding

- Slow response time

- Low efficiency (3%) andhigh maintenance cost

Early CO214 kW

UTIL Laser

Trumpf 4 kWCW Nd:YAG


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Lat est Laser Sys t em s Di rect D iode

- La te 90s t o p r esen t

- 1 0 k W - Hea t t r eat i ng and som e

c ladd ing - Large f i be r de l i ve r y - Low cost and h igh

ef f ici en cy ( 5 0 % )

- Poo r beam qua l i t y Fiber and D isk Lasers

- Ear ly 00 s - 1 0 s W t o 5 0 k W

- Diode pum ped

-

Lo w t o h i g h p ow er - Good beam q ua l i t y - Low m a in tenance cost - Sm a l le r f oo t p r i n t - H ig h ef f ici en cy ( > 2 5 % )

Early 4 kW

Direct DiodeLaser from Nuvonyx

TrumpfDisk Laser

Early 5 kWIPG Fiber Laser


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Diode Pu m ped Disk Laser



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Fib er Laser s

Overcoming Obstacles w ith Hybrid Robotic WeldingOvercoming Obstacles w ith Hybrid Robotic WeldingOvercoming Obstacles w ith Hybrid Robotic WeldingOvercoming Obstacles w ith Hybrid Robotic Welding


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Laser Remote Welding

Rem ot e Laser W e l d i n g

Designed tocompete againstresistance spotwelding

Use laser beam tomake stapleshaped lap welds

Continuouslymoving robot withlong stand offoptics

Can decreasewelding times>50%



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Remote Laser Welding



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Changes in lasers

Hybrid processing

- What is it?

- How is it being used?




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Hyb r id Laser Pr ocess ing


Hybr id Process Addresses disadvantages

of lasers and othertechnologies

Requires coordinationbetween power supply,laser, motion system, and

material feed system* Usually is associated with

hybrid laser arc welding(HLAW)- Provides filler material

for gap andmetallurgical

requirements- Lower heat input than

arc- Higher processing rates

Direction of Travel

Laser BeamGMAW Torch

Molten MaterialKeyhole

SolidifiedMaterial


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Laser Hot WireBrazingLaser Ho t W i re B raz ing

Applications

- Automotive BIW- Consumer products- Replacement for

resistance/sealer joints

Advantages- Very high speed

Compared toresistance weldedwith sealer

Elimination of sealer- No flux

No other consumable- Class A joint

Can be painted withminimal cleaning


2011 Dodge Challenger


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Hot W i re Cladd ing Applications

- Repair/Refurbish-

Tailored surfaces- Deposition of material- Digital manufacturing

Advantages- Vs Arc processes

Lower heat input Higher deposition

rates* Lower dilution Lower material cost*

- Vs Laser powder Lower power laser

Higher depositionrates* Higher yield Better feed control

Hot Wire CladdingCourtesy Alabama Lasers


Direction of Travel

Laser BeamGMAW Torch

Molten MaterialSolidifiedMaterial


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Aerospace App l i ca t ion s Address machining vs

fabrication Laser welding with filler

being accomplished fornext generation ofaircraft to address-- Weight- Fabrication cost- Maintenance- Material selection

Example- Airbus 380 hasover 5,000 sq meters ofstiffeners to skin in place

of riveted Al structure

Airbus 380



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Sh ip S t ru c tu r es App l i cat i ons Commercial ships

- Conventional welding results indistortion which increases cost:

Secondary processes tolevel- Procedural cost- Lifecycle cost for weight increase

Fit-up of assemblies

Military ships- Stripping of H beams for T

1/3 wasted from strippingprocess

Section is a compromise torolled product

Adds weight to final shipstructure

Examples:- Meyer Werft

Joining of material forbulkheads and decks

Stiffeners to panels- US Navy

Fabricated HSLA-65 fabricatedTs for CVN-78

Higher performance, lower

cost

CVN-78Wikipedia

Hybrid Welding atMeyer Werft



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Hybrid processing

- What is it?




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Chan ge in t he Mark e t Companies normally associated

with arc welding are nowinvolved in laser processing

Hybrid (combination of laserand GMAW) is of interestbecause it addresses the fit upissue for laser but provideshigher processing rates overGMAW

Applications include:- Shipbuilding- Oil and Gas

- Automotive- Aerospace- Consumer products


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Lin co ln Elect r ic s E f fo r t s

Pow er supp l y needs fo r l ase r hy b r i d app l i ca t i ons

Consumab le mod i f i ca t i ons

I n t e gr a t i on in t o au t o m at ed sy st em s

Pr ocess deve lopm ent and eva lua t ion



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Welding Output

Interconnect/

Interface

Laser Controls &

Command Reference Laser Feedback & Status

Laser

Output

Welding

Output

Welding Feedback:Current, Voltage,

Wire feed speed, etc

Laser Feedback:Power, temperature

Laser

Power

Supply

Welding

Power

Supply

Laser Output

Lincoln Patent Application #12254067filed on 10/20/08

Pow er Sup p ly Ef fo r t s

Na t u r a l Ex t e n si o n o f Po w e r Wave Wave fo rm Con t r o l

Techno logy Sing le Con t ro l l e r f o r t he

Process

Syn erg i c Opera t i on o f W e ld ing Cur ren t AND Laser Power

Seam less Adapt ive Cont ro l A rch i t ec tu re

Synchr on ized Sta r t i n g and Ending

Con t r o l To ta l Heat I npu t

La r g e N u m b e r o f I n v e n t i o n s i n Process w i th I P Team



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Consumab les Hybr id p r ocess

n o r m al ly m ean s l ow er d i l u t i on ; l eane r m a te r i a ls poss ib le

Arc st ab i l i zer s

less o f an issue Use o f so l id , m et a l

co r e , and f l ux co re

Trade o f f s

b et w een h i gh w i r e feed speeds vs l arg e d iam e te r w i r e s




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Au t om a t i on D iv i si on E f fo r t s

Build off existingengineered systems

Establish

development cell- 10 kW IPG Photonics

laser

- HighYAG Hybridwelding head

- Fanuc robot Workcell at Lincoln Electric;Automation Division



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Process Deve lopm en t and Eva lua t ion

Com pare hyb r i d p r ocesses aga ins t o t he r j o in ing and a rc processes

- Produc t i v i t y

- Economic - Per fo rmance

D ev e lo p m e n t o f n o v e l p rocesses

-

Bui ld o f f Linco ln s t r e n g t h s

- Address i nd u st r y / cu st o m er needs



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Hybrid processing

- What is it?




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Su m m a r y an d Conc lus ions

Advances in technology

are making robotichybrid processes viable

Centralized control of allof the subsystems willimprove theperformance

Further development isneeded in components,software, and

consumables Economics will drive the

implementation of hybridrobotic processes



4Hybrid Robotic Welding-Synergic Adaptive Evolution

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