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High-power welding with online seam tracking proves its mettle in the automotive industry

Process technology''s speed and precision requirements continue to press ahead, particularly in the area of automation. Across numerous sectors, the response is increased reliance on industrial robots for specific operations. Precisely to better harness the strengths of such robots – six degrees of freedom and a large working field of several meters – SCANLAB and Blackbird have developed a system solution that gives robots speed and highest accuracy in welding. The intelliWELD high-power scan head and the RobotSyncUnit controller are the main components of the system. In cooperation with BMW, the system was enhanced for position-critical seams via a coaxial illumination unit and a camera system by Lessmüller Lasertechnik GmbH, and successfully placed into series production.

Practical Test: Fillet Welding of Car Doors

Remote laser welding of galvanized steel surfaces (e.g. car doors) has required creation of a defined gap between the surfaces for degassing zinc. This time-intensive and costly preparatory step can be avoided by switching to alternative joint geometries, such as fillet seams. However, they require a level of precision during laser beam positioning that is unattainable without real-time sensors and control.

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  • SCANLAB AG