ROBOLASER: The Premium Laser Welder, Cutter, and Cladder - OR Laser

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ROBOLASER

One installation. Four technologies.

Welding - cutting - hardening - cladding

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Highlights

  • Quick and short cycle times
  • Precise and uniform high-quality parts
  • Flexible integration and manufacturing
  • Protection class IP67 for rough use conditions
  • Large selection of filler materials
  • Also permits welding of similar materials
  • Very high precision (layer thicknesses of 0.1 mm to several centimeters) through multiple layers
  • High hardness of 20 to 65 HRC
  • Low thermal stress
  • No structure damage
  • Compatible with CAD / CAM software solution ORLAS SUITE
  • Compatible with the powder feeder and powder nozzle

Custom-made surfaces: ROBOLASER makes it possible.

Welding, hardening, or deposition welding: OR Laser’s ROBOLASER offers a professional-grade robot-controlled laser system that permits a variety of different processing methods using a single laser. To achieve this highly customized functionality, the robo-laser uses multiple processing heads, which can be switched out in just minutes.

The processing heads: Variable control of the weld width.

Using a line scanner, the ROBOLASER creates track widths in excess of 15 mm without reducing the power density at the spot. This makes it possible for all seam types (butt welds, fillet welds, overlap welds) to weld components up to the highest industrial standards, even when the gap and position tolerances are too large for conventional laser welding.

The variability of the track width leads to further applications in the field of laser surface processing. The ROBOLASER stands out as an ideal unit for laser hardening and cladding with powder, and it’s exclusively for sale from OR Laser.

Optional: Operating via ORLAS SUITE

ORLAS SuiteThe ORLAS SUITE from OR Laser is an unprecedented new CAD/CAM environment for planning nearly all facets of laser processing: marking, engraving, cutting, welding, cladding, and powder-based additive manufacturing processes.

This is the first and only comprehensive software for industrial laser applications that is actually able to read and process all proprietary file formats and control all existing laser systems.

The ORLAS SUITE is excellently suited for supporting and planning processing strategies. The software supports the most popular 3D CAD file formats including STEP and IGES. The system also doubles as a tool for classic welding and marking tasks as well as powder-based laser cladding (also for depositing multiple layers).

Welding

Laser welding creates inseparable bonds between individual components. In this way, differentiation is made between surface heat conduction welding and deep welding, where the materials are melted at depth. The advantages of laser welding include the low thermal load for the material and the high speed of the process. As such, the ROBOLASER reaches a welding speed of around 2 m/min for stainless steel with a track width of approximately 1.6 mm and a melting depth of 1.4 mm, with a laser power of approximately 700 W.Customer sample production. Laser welding of stainless steel housing

Further Advantages

The high welding speed and the small weld width cause a clearly smaller heat-affected zone in the immediate vicinity of the weld during laser welding.

The resulting internal stress is thereby smaller than with conventional welding processes. Welding can be done with or without a filler material (e.g. wire).

Laser cutting

As a disjoining procedure the laser cutting counts as significant building block of the repertoire of laser applications.

A focused laser beam melts the material, and cutting gases blow the molten mass out of the joint gap. 

The relative speed between the cutting nozzle and the work piece creates a fine-cut edge, which does not need to be post-processed.

One of the advantages of this procedure is that complex geometries and contours can be produced quickly.

CAD/CAM systems define the cutting patterns and ensure highly effective material usage.

Another well-known property of this quasi-touchless procedure is the minimal thermal deformation due to the low heat input.

 

application example laser cutting

Laser cutting

Laser cladding with powder

In the case of laser cladding with powder, a gas mixture with fine metal powder is supplied. The metal powder melts at the heated location and connects itself with the workpiece.

In addition to manual laser welding with wire, this procedure is another way to quickly process components weighing up to several tons.

The method both is cost-effective and has the precision of an industrial robot. Considering the sizable costs of unused downtime, this technology offers an enormous cost advantage, as the material deposition is performed close to the final contours.

Applications for laser cladding with powderapplication example laser powder cladding

In industrial applications, laser cladding with powder is used mainly fully automated, but it may also be done manually.

In the following situations, laser cladding with powder is ideal:

A large selection of powdery materials / Build-up of armour coats on tools such as drill heads, rail vehicles, and land vehicles / Model change and modification instead of new manufacturing / Repairing of manufacturing defects / Injection moulding tools / Forming tools / Engine manufacturing / Mechanical engineering / Forge tools / Die-casting tools / Repairing and processing of parts that cannot be repaired with conventional techniques / Build-up of 3-D contours / Repair of wear parts

Application of a wear protection via laser powder claddingApplication of a wear protection layer onto a knife by means of laser powder cladding

Hardening

Laser hardening is intended to increase the mechanical resistance of the material. It is also called surface-layer hardening. Heat treatment followed by rapid cooling effects selective change and transformation of the structure.

The laser heats the material locally to just below the temperature of the weld pool while moving along the surface to be hardened. This rapid cooling leads to formation of the hardened layer.

Track widths up to 15 mm can be created with the processing heads offered by OR Laser.

application example laser hardening

another application example of laser hardeningLaser hardening for increase of the mechanical strength of the cutting edge

Materials engineering

The table shows an overview of the employed powders and the hardness that can be realized.

Essentially, all usual plastic mold steels and powder-metallurgical steels (e.g. ASP, CPM, and similar) and aluminum alloys can be processed with laser deposition welding. The ROBOLASER can work with filler materials including cobalt-, nickel-, aluminum-, and iron-based alloys. Depending on the metals used, hardening may range from 20 to 63 HRC.

Parent metalFiller materialsHardening in the applied layer
Steels for plastics processingCobalt, nickel and iron based alloys20 to 63 HRC
Powder-metllurgical steelsIron based alloys58 to 63 HRC
Aluminum alloysAluminum alloys75 HV 0.3 to 170 HV 0.3

Robolaser Equipment

  • min. 1 kW laser
  •  Industrial robot + tilt rotation axis
  • Welding optics and optical waveguides
  • Special nozzles
  • Powder feeder

industrial welding robot

Laser
LRS12001200WLRS160
LasertypePulsed lamp pumped Nd:YAGFaserlaserPulsed lamp pumped Nd:YAG
Pulse peak power6,0 kW7,5 kW
Max. pulse energy60 J80 J
Pulse duration0,2 - 20 ms0,2 - 20 ms
Pulse frequency1,0 - 100 Hz1,0 - 100 Hz
Focus diameter0,2 - 2,0 mm0,150,2 - 2,0 mm
Line voltage (V/Ph/Hz)400/3/50400/3/50
Weight laserheadca. 170 kgca. 170 kg
max. Arbeitshöheca. 1200 mmca. 1200 mm
Verfahrweg der X / Y - Achsenx = 150 mm / y = 150mmx = 150 mm / y = 150mm
Hub der Z - AchsezLaser = 300mm, zTable = 400mm zLaser = 300mm, zTable = 400mm
Abmessung des Arbeitstisches ( BxL )(400 x 250) mm(400 x 250) mm
Weight supply unit250kg250kg
max. Durchschnitsleistung120 Watt160 Watt
Abmessung der Anlage (b/l/h)(950 x 1300 x 1200) mm(950 x 1300 x 1200) mm
Internes Wasser / Luft Kühlsystemjaja
ExternesWasser / Luft Kühlsystemoptionaloptional
Stereomikroskop Vergrößerung10x10x
Sehfelddurchmesser16mm16mm
Schwenkoptikoptionaloptional
Autofokusoptionaloptional
optionaloptional
Lasersystem
  • Hermetically closed laser source with connection for optical waveguide
  • Interface with hardware monitoring function
  • laser pointer
  • Industry controller for adjustment and indication of power, pulse duration, pulse repetition frequency with external trigger via I/O, internal water-water cooling system
Processing optics
  • Variable beam expansion
  • Line scanner
  • Beam deflection
  • Protective glass
  • Focusing lens
Mechanik
  • 26 kg load capacity
  • Compact control
  • 1.5 work area
  • Rotation and tilt module (max 500 kg load capacity)
  • I/O modules
  • Touch screen operation display
  • Software expansion and laser control
Dimensions and weight

Dimensions and weight (robot head)

Dimensions: Width 100 mm x height 200 mm x length 500 mm
Weight: 159 kg net

Dimensions and weight (Robot)

Work area: W 4000 mm x H 2000 mm x L 2000 mm
Weight: 400 kg net