Presentation SOUTRAC® Non-Linear Weld System Soudronic

Presentation SOUTRAC®
Non-Linear Weld System
SOUTRAC - The Future for Welding
AHSS Tailored Blanks
w w w . a u t o Automotive
steel.org
Soudronic
SOUTRAC®
Characteristic of Parts
Linear
Linear shifted
Non linear
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Body Side /
Body Side /
Closures 2002
Closures 2005
O thers 2002
O thers 2005
Tunnel/Wheelh.
Tunnel/Wheelh.
Pillars 2002
Pillars 2005
Rails 2002
Rails 2005
Volume in M io. TB
SOUTRAC®
Market Share Non-linear Tailored Blank
non linear
linear
Application oriented
70
60
50
250
30
20
10
50
0
0
Market volume total
40
200
150
100
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2000
2005
SOUTRAC®
The Solution
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SOUTRAC®
The Solution
max. speed:
30 m/min
max. acceleration: 4 m/s2
max. speed:
120 m/min
max. acceleration: 4 m/s2
y-a
xis
is
x
a
x-
weld speed:
min. radius:
2...18 m/min
100 mm
max. blank size: 2200 x 3600 mm
max. # of blanks: 4
max. # of welds: 12
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SOUTRAC®
The Solution
Edge tracking
Gap bridging
Weld process
Quality control
SOUVIS® 2
Function groups
SOUTRAC®
Laser head
SOUVIS® 1
SOUKA®
Edge position
measurement
Mechanical gap
closing
SOUVIS® 1
(SOUVIS®
5000)
• Edge position
measurement
• Gap determination
• Monobloc
• Process gas
• Laser position
control
Seam profile top
Seam profile root
SOUVIS® 3
Seam
homogeneity
Laser head
SOUVIS® 2
•
•
•
•
•
(SOUVIS® 5000)
• Seam profile
top
• Seam
homogeneity
Monobloc
Process gas
Laser position control
Gap driven filler wire
Double spot
SOUTRAC® combines all functions in only 3 groups
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SOUTRAC®
The Solution - Absolute Accuracy of Main Axes
=1
00
m
m
0.1 mm
R
y-axis, weld head
V = 12 m/min
Nominal weight
of weld shuttle
4000 kg
Nominal weight
of weld head
300 kg
Nominal position
Measured position
x-axis, weld shuttle
Maximum absolute
deviation
0.05 mm
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SOUTRAC®
The Solution - Following a non-linear weld line...
Main axis y
SOUVIS® 2
SOUVIS® 1
Rotation axis
SOUVIS® 2
Rotation axis
laser head
Main axis x
Laser head
Requirement for quality welds:
Swivel axis
SOUVIS® 2
Swivel axis
SOUVIS® 1
Following precisely a curved
contour with 3 different function
groups each positioned normal to
the weld line
Weld line
Solution:
Besides 2 main axes for the main
movement (x,y), we need 5
numerically controlled axes
integrated into the weld head
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Rotation axis
SOUVIS® 1
SOUTRAC®
Following a non-linear weld line... (cont.)
Requirement for
quality welds:
Welding different blank
gauges in the same weld
cycle, even T-shaped
combinations can occur.
Laser head
SOUVIS® 1
Solution:
Each function group has
its own independent
numerically controlled
height (z-) axis.
Weld line
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SOUVIS® 2
SOUTRAC®
Following a non-linear weld line... (cont.)
Actual edge position
Image size SOUVIS®
1+2: 10 x10 mm
Pre-programmed
edge position
Requirement for quality
welds:
Following precisely a
curved contour even if the
pre-programmed line does
not fit with the actual edge
position
CNC: Ring
buffer for
correction
numbers and
position-driven
laser axis
correction
Solution:
Position dependent edge
tracking and positiondriven correction of the
laser head normal to the
actual weld line
Deviation calculation
at actual position
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Laser head with
correction axis
normal to weld line
SOUVIS® 1
edge tracking
SOUTRAC®
Varying Gaps....
Position dependent
gap
Laser head with
filler wire capability
CNC: Ring buffer for
gap width and control
of position-driven filler
wire speed
Requirement for quality
welds:
Overcome varying gap width
up to 0.3 mm
Wire
feeder
Solution:
Position dependent gap width
measurement and
corresponding control of wire
feeding speed
Gap width at actual
position
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SOUVIS® 1
gap determination
SOUTRAC®
Mechanical solution for the weld head
Rotation axis
laser head
Laser light cable
Swivel axis
SOUVIS 2
Swivel axis
SOUVIS 1
(Patent pending)
Gap driven filler wire
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SOUTRAC®
Welding Demonstration
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SOUTRAC®
Gap Issue in Non-Linear Welding Applications
There is a higher risk of the gap problem in the non-linear Tailored Blanks
welding process due to the sum of geometrical tolerances.
Therefore a safe solution for the gap closing prior to welding process is
mandatory.
Only then a safe and reliable high production output can be guaranteed!
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SOUTRAC®
What is a Gap?
Gap = Missing material
Possible causes of gap:
Released tension during blanking
Tolerance of part measurement and/or positioning
Large die gap
Damage during transportation/handling
…………………
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SOUTRAC®
Steel Formability Effects on Edge Quality
Shear to break ratio
and material deficit
Mild Steel
Same shear gap
AHSS
Blanking is a Forming Process:
Good formability of mild steel means good blanking ability
Limited formability of AHSS means bad blanking ability
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SOUTRAC® Solution
Automatic Adjustment of Filler Wire Speed
Filler wire speed (m/min.)
Gap width (mm)
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SOUTRAC® Solution
Automatic Adjustment of Laser Position
Position (mm)
Gap width (mm)
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SOUTRAC® Solution
The End Result
Gap 0.38 mm
Corresponding weld with
controlled filler wire
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SOUTRAC® Solution
500
600
Examples of Hardness Profiles
500
600
Hardness HV1
400
350
300
250
200
150
500
400
Härte HV1
Hardness HV1
450
300
200
100
100
0
0
0
0.2
0.4
0.6
0.8
1
1
[ mm]
1.2
1.4
1.6
1.8
2
G
DP 14001400
G // DOCOL
0
0
50
A / TRIP 600
2
Distance from seam centre [mm]
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0
0
0
0.2
0.4
0.6
0.8
1
1
1.2
1.4
1.6
1.8
Distance from seam centre [mm]
2
2
SOUTRAC®
Integration of SOUVIS® 5000 Inline Quality System
SOUVIS® 1
SOUVIS® 2
Profile analysis
Seam homogeneity analysis
Edge position determination
Gap width determination
Laser head
Integrated position control axis
Gap driven filler wire
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SOUVIS® 5000
Sensor Principle
10 mm
CMOS Camera with adaptive
response characteristics
10 mm
Short pulse
flash light
Diode
laser line
(Patent pending)
Combined acquisition of
gray scale image and
laser triangulation line
Resolution
Max. speed
Max. data flow
0.01 mm
30 m/min
60 MB/s
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SOUVIS® 5000
One Sensor for all Requirements
No complicated and diffuse
fuzzy logic necessary to
combine multiple sensor
arrangements
Easy to operate,
Low number of
parameters
Extraction of seam
geometry information
Extraction of seam
homogeneity information
Reduced maintenance and
spare parts requirements
Microscopic resolution and outstanding
discrimination capabilities (human eye
is the standard)
Easy to integrate
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SOUVIS® 5000
SOUVIS® 1 Edge Tracking
Determination of
• Edge position (laser position
control)
• Gap width (wire feeding control)
• Blank gauge difference
• Blank alignment
• Edge quality
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SOUVIS® 5000
SOUVIS® 2 Quality Control
Determination of
•
•
•
•
•
•
•
•
•
Seam concavity
Seam convexity
Mismatch
Seam width
Seam roundness
Lack of penetration
Porosity
Expulsion
Pinholes
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SOUVIS® 2
Image Analysis
Texture analysis
Pore analysis
Profile analysis
Upper seam
surface of a
tailored blank
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SOUVIS® 2
Gray Scale Image Analysis
Reasons for Failure
Local edge defects
Plasma absorption
Expulsions, holes
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Missing texture
SOUVIS® 2
Gray Scale Image Analysis
Reason for failure
Partial evaporation of dirt or zinc
particles located between the weld
edges
Porosity
0.1 mm x 0.3 mm
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SOUVIS® 5000
Summary
ƒ A safe online quality control is a must for an efficient
production of non-linear tailored blanks.
ƒ Its not sufficient to detect some of the relevant weld
failures and some not.
ƒ SOUVIS® 5000 represents the only integrated solution
today capable of detecting all relevant failures in nonlinear tailored blanks.
ƒ SOUVIS® 5000 performs with only one unique sensor, i.e.
less complexity and more reliability.
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SOUTRAC®
Example Part
Golf Door (non linear)
Cycle Time:
5
10.5sec / TB
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SOUTRAC®
Example Part
GMT 370 Body Side
Cycle Time:
6
36sec / TB
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SOUTRAC®
Example Part
A-MPV (PQ35)
Cycle Time:
7
25sec / TB
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SOUTRAC®
Example Part
Honda New Accord Front Door Upper
1346
1288
Cycle Time:
8
16.0 sec / TB
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SOUTRAC®
Example Part
ROVER 75 Front Door)
Cycle Time:
9
12.5sec / TB
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SOUTRAC®
Production System for Body Side
Tailored Blanks Platinen
A-MPV Seitenteil Innen
4teilige Platine
ZStE260 Z 100 MB 1,2mm
ZStE220 Z 100 MB 1,0mm
alternativ: ZStE220i Z 100 MB 1,0mm
Walzrichtung
ZStE220 Z100 MB 1,5mm
alternativ: ZStE220i Z 100 MB 1,5mm
ZStE260 Z 100 MB 1,0mm
Walzrichtung
550mm
Walzrichtung
2000mm
Walzrichtung
2600mm
Schulz-Marner Stand: 11.00 (K:\...\A_MPV_SLW\Bilder\St_innen_Neues_Konzept\A_MPV_ST_i_2_tei_2l)
Produktionstechnik Marke Volkswagen
PP-F1
Cycle time per side ring 25 sec.
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SOUTRAC®
Production System for Body Side
Cycle time
15.8 sec
16.3 sec
17.0 sec
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SOUTRAC®
Production System for Body Side
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SOUTRAC®
Layout
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SOUTRAC®
Summary
Soudronic SOUTRAC®
The right solution to meet the high
market demand !
regarding
- high output of quality Tailored Blanks
- low scrap rate
- high uptime
based on
- 20 years of experience
- 38 Mash Seam TB welding lines
- 54 Laser Seam TB welding lines (11- 02)
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