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VW Golf VLaser Processing
Concept and Production Implementation
Tim Morris, TRUMPF Inc., Laser Technology Center
Information Provided by:Klaus Loeffler,Volkswagen AG,
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History of laser applications in Body in White at Volkswagen.
Laser applications in Body in White of the Volkswagen Golf V- Data of the Body in White production line- Laser applications
Laser BrazingLaser CuttingLaser Welding
Outlook
Outline
Conclusions based on ½ year production
VW Golf V: Concept and Implementation in Production
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History of Laser Applications in Body in White at VW
Roof joint
Start 1993
1996 1997 1998 1999 2000
Roof jointTrunk lid
Roof joint Trunk lidUB-Side panel Rocker panelSide panelB-pillar
Roof joint Trunk lidUB-Side panel Rocker panel Side panelB-pillar
2001 2003
Roof jointTrunk lidUB-Side panelSide panelB-Pillar Front module
2002
Roof joint Trunk lidUB-Side panel Side panelB-PillarUnderbody Hood
Roof joint
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050
100150200250300350400450
1995 1996 1997 1998 1999 2000 2001 2002 20032004 2005
Lasers
Units
History of Laser Applications in Body in White at VW
VW laser Installed Base 580
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History of laser applications in Body in White at Volkswagen.
Laser applications in Body in White of the Volkswagen Golf V- Data of the Body in White production line- Laser applications
Laser BrazingLaser CuttingLaser Welding
Outlook
Outline
Conclusions based on ½ year production
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~ 2,600 spotsResistant Spot Welds~ 6,000 mmMIG/MAG-Welding~25,000 mmAdhesive~56,000 mmLaser Weld/Braze
Distribution of the Various Joining Technologies
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Laser application: Laser Welding (with and without filler material)Laser BrazingLaser Cutting
Locations: Wolfsburg, Mosel, Brüssel
Location: Wolfsburg TotalLaser technology: 150 4kW Nd:YAG Laser (TRUMPF HL4006D)250
1 1kW Nd:YAG Laser (TRUMPF HL1003D) 3250 Laser welding heads 420
3 Laser cutting heads 9
Infrastructure: 24 MW Electrical consumption (Laser) 40 MW23 MW Cooling capacity (Laser) 38 MW
Capacity: 2,000 Cars/day >3,000140Km Laser joint length/day >210Km
Laser Technology
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Joining Strategy
UB II Auss.Underbody IIUnderbody I UB I Auss.
Underbody front
L rail front right
L Rail front left
Underbody back compl.
Underbody back
Ltr back L/R
FirewallWheelhouse
front L/R
Wheelhouse back L/R
Back panel
Framing-station Welding I Finish
Doors front/back/left/right
Closure front and back
Inner front Side panel
Side panel left
Inner back side panel
Assembly Anbaut.
Welding II
Inner front Side panel
Inner back Side panel
UB II Auss.
Roof/SAD
Side panel right
Fender li/re
Welding III
Mainline
Laser Systems
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Body Side Lines
Goal: Cycle time 30 Seconds
Solution: Headstock & Tailstock positioner
Advantage: High utilization of the laser resonatorFlexibility (Products)Floor space reduction
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Laser Brazing on Body Side Process Parameters:
Braze Wire: CuSi3; 1.6 mm
Laser Power: 3,500 W
Fiber Diameter: 0.6 mm
Travel Speed: 2.1 m/min
Joint Gap: 0...0.5 mm
Body Side Lines
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Joining Strategy
UB II Auss.Underbody IIUnderbody I UB I Auss.
Underbody front
L rail front right
L Rail front left
Underbody back compl.
Underbody back
Ltr back L/R
FirewallWheelhouse
front L/R
Wheelhouse back L/R
Back panel
Framing-station Welding I Finish
Doors front/back/left/right
Closure front and back
Inner front Side panel
Side panel left
Inner back side panel
Assembly Anbaut.
Welding II
Inner front Side panel
Inner back Side panel
UB II Auss.
Roof/SAD
Side panel right
Fender li/re
Welding III
Main line
Laser Systems
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Reduction in Manufacturing Time: Example Roof Joint.
Body in White: Framing & Welding Laser Brazing
Paint: Sealer
Assembly: Roof ditch cover installation
Framing-Station: Roof Joint
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Example: Framing-Station
Basic data:14 Laser HL4006D3,400mm Laser brazing5,340mm Laser welding68 s Cycle time40% Floor space reduction
The system is designed to cover all Volkswagen PKW products:Lupo to Touareg.
Lasers can be used in a second parallel weld station during loading/fixturing/unloading in the framing station.
Manufacturer:Vorrichtungs- und Werkzeugbau, Wolfsburg
Framing-Station
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Joining Strategy
UB II Auss.Underbody IIUnderbody I UB I Auss.
Underbody front
L rail front right
L Rail front left
Underbody back compl.
Underbody back
Ltr back L/R
Fire wallWheelhouse
front L/R
Wheelhouse back L/R
Back panel
Framing-station Welding I Finish
Doors front/back/left/right
Closure front and back
Inner front Side panel
Side panel left
Inner back side panel
Assembly Anbaut.
Welding II
Inner front Side panel
Inner back Side panel
UB II Auss.
Roof/SAD
Side panel right
Fender li/re
Welding III
Main line
Laser Systems
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Flexible Laser Welding Cell:
Eliminates the use of any product specific fixturing. Possible by the use of universal optics with integrated universal fixturing.
Universal fixturing: WheelDouble WheelSplitter WheelSingle and double finger
Advantage:
• Created the possibility to run different products on the same line.
• Flexibility in terms of changes in demand for one product.
• Model changeover is possible in a efficient and timely manner.
Construction: Typical Laser Welding Cell
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Joining Strategy
UB II Auss.Underbody IIUnderbody I UB I Auss.
Underbody front
L rail front right
L Rail front left
Underbody back compl.
Underbody back
Ltr back L/R
FirewallWheelhouse
front L/R
Wheelhouse back L/R
Back panel
Framing-station Welding I Finish
Doors front/back/left/right
Closure front and back
Inner front Side panel
Side panel left
Inner back side panel
Assembly Anbaut.
Welding II
Inner front Side panel
Inner back Side panel
UB II Auss.
Roof/SAD
Side panel right
Fender li/re
Welding III
Mainline
Laser Systems
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Challenge:A slight variation on the geometrical position of the mounting plate for the front end is based on tolerances throughout the manufacturing process of the auto body. In order to maintain the narrow gap tolerances of VW, it is necessary to reduce the slight variation.
Solution:Optical measurement of the auto body.Cut to length of the front rail to the individual length.Joining of the mounting plate to the front rail at the designed relative location.
Mounting Front Plate Module
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Goal: To optimize the geometricposition of the mounting plate for the body front to eliminate additional alignment during final assembly.
Optical measurement of each body.
Mounting Plate - Front Module
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Step 1: Optical measurement of each body.Optical measurement system.
Mounting Plate Front Module
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Correction of the robot program based on the individual measured data of the body.
Cut to length of the front rail to the X-Location.
Cutting optic and welding optic mounted on one robot.
Mounting Plate Front Module
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One robot holds the mounting plate in place (Calculated Y and Z-location).
The safety critical laser weld is controlled by a process monitoring system.
Mounting Plate Front Module
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Joining Strategy
UB II Auss.Underbody IIUnderbody I UB I Auss.
Underbody front
L rail front right
L Rail front left
Underbody back compl.
Underbody back
Ltr back L/R
FirewallWheelhouse
front L/R
Wheelhouse back L/R
Back panel
Framing-station Welding I Finish
Doors front/back/left/right
Closure front and back
Inner front Side panel
Side panel left
Inner back side panel
Assembly Anbaut.
Welding II
Inner front Side panel
Inner back Side panel
UB II Auss.
Roof/SAD
Side panel right
Fender li/re
Welding III
Mainline
Laser Systems
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Monitoring of the actual laser power at the workpiece after each cycle
Graphical display
Optic
Sensorhead
Sensor Electronics
Laser power above specified
limit for the welding process
Laser power is reaching lower
limit
Laser power below specified limit for
the welding process
Process Quality
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Customization of Cars After Paint
Right hand-OptionGPS-Antenna
Roof-Rail
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History of laser applications in Body in White at Volkswagen.
Laser applications in Body in White of the Volkswagen Golf V- Data of the Body in White production line- Laser applications
Laser brazingLaser cuttingLaser welding
Outlook
Outline
Conclusions based on 1.5 years production
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Stiffness Golf V v.s. Golf IV
100%
StaticTorsion Stiffness
DynamicalTorsion Stiffness
DynamicalBending Stiffness
+80%
+15%+35%
Golf IV Golf V
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Goals reached:
- Increased process speed (joining).- Increased productivity- Short cycle times (30 Seconds)- Increased strength of the modules compared to most alternative joining methods- Reduced heat distortion - Narrow or no flange => Weight reduction- High flexibility due to the possibility to direct the laser beam by the means of Laser Light Cabels into different workcells.
- Reduced floorspace
Conclusions Based on 1½ Years Production
320 m2480 m2Floorspace Underbody
70 m3 mLength of laser weld2,6004,608# of Spot Welds
(-50%)1472 m22816 m2Floorspace Side panel Golf VGolf IV
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Training Programs in all Areas: Design dept. of the carPlanning dept. of the production linesSystem manufacturerProduction (plant)
Additional Requirements - Plant Level: Laser technologyLaser-beam-generatorLaser application/processTooling/partsOptics and mechatronicIT-Network / control technology
The workforce with the required training is not available on the present labor market
=Intensive education programs
for the employees.
Conclusions Based on 1½ Year Production
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History of laser applications in Body in White at Volkswagen.
Laser applications in Body in White of the Volkswagen Golf V- Data of the Body in White production line- Laser applications
Laser brazingLaser cuttingLaser welding
Outlook
Outline
Conclusions based on ½ year production
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Outlook
The implemented laser technology has shown to be robust and reliable.
Necessary improvements: Laser Resonator/Beam DeliveryLaser efficiency 20%Beam quality 6 mm*mradLaser power 6000W
Length of light cables 100mUp-Time 99,9%Max. time to repair 30 Min.
Laser Processing OpticsRobust optics, ready for production.
Laser processRobust process, large process windowSelf controlled/aligned process.
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YAG Scanner Implementation
• Galvanized Body Component• Simple Robot Motion• Complex Weld Shapes by Scanner
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