w w w . a u t o s t e e l . o r g Presentation SOUTRAC Presentation SOUTRAC ® ® Non Non - - Linear Weld System Linear Weld System SOUTRAC SOUTRAC - - The Future for Welding The Future for Welding AHSS Tailored Blanks AHSS Tailored Blanks Soudronic Automotive Soudronic Automotive
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Presentation SOUTRACPresentation SOUTRAC®®
NonNon--Linear Weld SystemLinear Weld System
SOUTRAC SOUTRAC -- The Future for Welding The Future for Welding AHSS Tailored BlanksAHSS Tailored Blanks
max. blank size: 2200 x 3600 mmmax. # of blanks: 4max. # of welds: 12
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SOUKA®
Mechanical gap closing
Gap bridging Edge tracking Weld process Quality control
Func
tion
grou
ps
SOU
TRA
C®
SOUVIS® 1Edge position measurement
Laser head• Monobloc• Process gas• Laser position
control
SOUVIS® 2Seam profile topSeam profile root
SOUVIS® 3Seam homogeneity
SOUVIS® 1 (SOUVIS® 5000)• Edge position
measurement• Gap determination
Laser head• Monobloc• Process gas• Laser position control• Gap driven filler wire• Double spot
SOUVIS® 2(SOUVIS® 5000)• Seam profile
top• Seam
homogeneity
SOUTRAC® combines all functions in only 3 groups
SOUTRACSOUTRAC®®
TheThe SolutionSolution
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SOUTRACSOUTRAC®®
TheThe Solution Solution -- Absolute Absolute AccuracyAccuracy of of MainMain AxesAxes
R =
100
mm
0.1 mm
x-axis, weld shuttle
y-ax
is, w
eld
head
V = 12 m/min
Measured position
Nominal position
Nominal weight of weld shuttle 4000 kg
Nominal weight of weld head 300 kg
Maximum absolute deviation 0.05 mm
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Main axis y
Main axis x
SOUVIS® 2 SOUVIS® 1
Laser head
Rotation axislaser head
Swivel axisSOUVIS® 1
Weld line
Rotation axisSOUVIS® 1
Swivel axisSOUVIS® 2
Rotation axisSOUVIS® 2
Requirement for quality welds:Following precisely a curved contour with 3 different function groups each positioned normal to the weld line
Solution:Besides 2 main axes for the main movement (x,y), we need 5 numerically controlled axes integrated into the weld head
SOUTRACSOUTRAC®®
The Solution The Solution -- FollowingFollowing a nona non--linear linear weldweld line...line...
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SOUTRACSOUTRAC®®
FollowingFollowing a nona non--linear linear weldweld line... line... (cont.)(cont.)
Requirement for quality welds:Welding different blank gauges in the same weld cycle, even T-shaped combinations can occur.
Solution:Each function group has its own independent numerically controlled height (z-) axis. Weld line
SOUVIS® 2SOUVIS® 1
Laser head
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Actual 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
Solution:Position dependent edge tracking and position-driven correction of the laser head normal to the actual weld line
Pre-programmed edge position
Image size SOUVIS®
1+2: 10 x10 mm
SOUVIS® 1 edge tracking
Deviation calculation at actual position
CNC: Ring buffer for correction numbers and position-driven laser axis correction
Laser head with correction axis normal to weld line
SOUTRACSOUTRAC®®
Following a nonFollowing a non--linear weld line... (cont.)linear weld line... (cont.)
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SOUTRACSOUTRAC®®
Varying Gaps....Varying Gaps....
Requirement for quality welds:Overcome varying gap width up to 0.3 mm
Solution:Position dependent gap width measurement and corresponding control of wire feeding speed
Position dependent gap
SOUVIS® 1 gap determination
Laser head with filler wire capability
Gap width at actual position
CNC: Ring buffer for gap width and control of position-driven filler wire speed
Wire feeder
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SOUTRACSOUTRAC®®
Mechanical solution for the weld headMechanical solution for the weld head
Laser light cable
Rotation axis laser head
Gap driven filler wire
Swivel axisSOUVIS 2
Swivel axisSOUVIS 1
(Patent pending)(Patent pending)
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SOUTRACSOUTRAC®®
Welding DemonstrationWelding Demonstration
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SOUTRACSOUTRAC®®
Gap Issue in NonGap Issue in Non--Linear Welding ApplicationsLinear 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 pTherefore a safe solution for the gap closing prior to welding process is rocess is mandatory.mandatory.
Only then a safe and reliable high production output can be guaranteed!
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Gap = Missing materialGap = Missing materialPossible causes of gap:Possible causes of gap:
Released tension during blankingReleased tension during blankingTolerance of part measurement and/or positioningTolerance of part measurement and/or positioningLarge die gapLarge die gapDamage during transportation/handlingDamage during transportation/handling……………………………………
SOUTRACSOUTRAC®®
What is a Gap?What is a Gap?
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Blanking is a Forming Process:Good formability of mild steel means good blanking ability
Limited formability of AHSS means bad blanking ability
Shear to break ratio and material deficit
Mild SteelSame shear gap
AHSS
SOUTRACSOUTRAC®®
Steel Formability Effects on Edge QualitySteel Formability Effects on Edge Quality
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Filler wire speed (m/min.) Gap width (mm)
SOUTRACSOUTRAC®® Solution Solution Automatic Adjustment of Filler Wire SpeedAutomatic Adjustment of Filler Wire Speed
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Position (mm) Gap width (mm)
SOUTRACSOUTRAC®® Solution Solution Automatic Adjustment of Laser PositionAutomatic Adjustment of Laser Position
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Gap 0.38 mm Corresponding weld withcontrolled filler wire
SOUTRACSOUTRAC®® Solution Solution The End ResultThe End Result
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G / DOCOL 1400
0
100
200
300
400
500
600
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Här
te H
V1
A / TRIP 600
0
50
100
150
200
250
300
350
400
450
500
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
[ mm]0 1 2
Distance from seam centre [mm]
0 1 2
Distance from seam centre [mm]
Har
dnes
s H
V1
0
5 00
Har
dnes
s H
V1
0
600
G / DP 1400
SOUTRACSOUTRAC®® Solution Solution Examples of Hardness ProfilesExamples of Hardness Profiles
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SOUVIS® 1Edge position determinationGap width determination
SOUVIS® 2Profile analysis
Seam homogeneity analysis
Laser headIntegrated position control axis Gap driven filler wire
SOUTRACSOUTRAC®®
Integration of SOUVISIntegration of SOUVIS®® 5000 Inline Quality System5000 Inline Quality System
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CMOS Camera with adaptive response characteristics
Diode laser line
Combined acquisition of gray scale image and
laser triangulation line
10 mm10 m
m
Resolution 0.01 mmMax. speed 30 m/minMax. data flow 60 MB/s
ZStE220 Z 100 MB 1,0mm alternativ: ZStE220i Z 100 MB 1,0mm
ZStE260 Z 100 MB 1,2mm
2000
mm
550m
m
2600mm
ZStE260 Z 100 MB 1,0mm
ZStE220 Z100 MB 1,5mm alternativ: ZStE220i Z 100 MB 1,5mm
Wal
zric
htun
g
Walzrichtung
Walzrichtung
Walzrichtung
SOUTRACSOUTRAC®®
Production System for Body SideProduction System for Body Side
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Cycle time
15.8 sec
16.3 sec
17.0 sec
SOUTRACSOUTRAC®®
ProductionProduction System forSystem for Body SideBody Side
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SOUTRACSOUTRAC®®
ProductionProduction System forSystem for Body SideBody Side
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SOUTRACSOUTRAC®®
LayoutLayout
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SOUTRACSOUTRAC®®
SummarySummary
SoudronicSoudronic SOUTRACSOUTRAC®®
The right solution to meet the high The right solution to meet the high market demand !market demand !
regardingregarding-- high output of quality Tailored Blankshigh output of quality Tailored Blanks-- low scrap ratelow scrap rate-- high uptimehigh uptime
based onbased on-- 20 years of experience20 years of experience-- 38 Mash Seam TB welding lines38 Mash Seam TB welding lines-- 5454 Laser Seam TB welding lines Laser Seam TB welding lines (11(11-- 02)02)