Customer A, based in Bulgaria, specializes in the production of aluminum alloy ladders. They were initially seeking a welding robot solution to enhance their production efficiency.

After a factory visit, the customer was recognizing our expertise as a provider of professional welding robot workstation solutions. They decided to send samples for welding tests.

Upon receiving the samples, we discovered that the weld seams were excessively large, making welding unfeasible.

Further investigation revealed that the client's current manufacturing process involved manual cutting and welding, resulting in significant workpiece inaccuracies.

To address the issue, we recommended that the customer first improve the quality of their workpieces by using an automatic aluminum pipe and profile circular saw cutting machine.

The customer adopted the new aluminum pipe circular saw cutting machine, which significantly improved their product quality.

They sent us new samples for further testing again.

Considering the large size of the products they manufacture, we designed a welding robot workstation solution featuring ground rails and 2 sets of positioners to accommodate their needs.

Once the equipment was completed, the customer come to our factory for acceptance testing and received comprehensive training from our engineers.

The equipment was then shipped to the client's facility in Bulgaria, where it was quickly put into operation.

Customer Case

Project name: BYD

Material: High-strength steel

Main product details

Note: the welding speed need to meet 5 m/min

Technical requirements

1. Welding seam position: The product adopts 4-pass laser welding, the specific position is shown in the figure below:

2. Appearance requirements

* Overall appearance requirements: No corrosion, rust, metal debris, oil stains, water marks & water stains as a whole. No water or oil is allowed to be stored in the steel cavity;

* Rolling beam assembly surface: The surface is smooth and clean, without defects such as pits, convex bumps, welding slag, bump marks, distortions, etc.; the welding joint has a smooth transition;

*The burrs cut off at the end are ≤0.3mm, and the hands will not be cut if touched by hand;

*The weld surface should be smooth and uniform in width. Defects such as cracks, missing welds, false welds, spatter, pores, undercuts, burn-throughs, and unwelded joints are not allowed. The weld protrusion on the non-assembly surface should be ≤0.3.

3. Welding seam technical requirements

* 0.5mm≤weld width≤1.5mm 

* The penetration depth of the second plate during stack welding ≥ 0.5mm

* Welding strength≥ 90% of the base metal.

Professional solutions

Solution: ST-OLW Online Laser Welding Machine

Power: 12000W

Result: After rigorous testing and acceptance, the customer purchased 6 sets of ST-OLW series online laser welding machines at one time. After using online laser welding, we helped customers solve the problem of producing new products that could not be produced by traditional high-frequency welding methods.

Introduction to online laser welding technology

Online laser welding is an efficient and precise welding method that uses a high-energy laser beam to directly act on the surface of the material, causing the material to melt and solidify rapidly to form a strong weld.

Whether it is a traditional oil vehicle or a new energy vehicle, in the current environment of cost reduction, efficiency improvement and efficient production, metal profiles such as automobile exhaust pipes and battery trays are widely used in one-piece online laser welding.

Laser, as a new type of non-contact welding method, has greatly improved production efficiency and process intensity.

Advantages of online laser welding technology

1. High efficiency: The speed of laser welding far exceeds that of traditional welding methods, greatly improving the work efficiency of the production line.

2. High quality: Laser welding can achieve precise control, high weld quality, and greatly reduce subsequent repair work.

3. Low thermal impact: The heat affected area of laser welding is small, which reduces the thermal deformation of the material and ensures the dimensional accuracy of the product.

4. Strong material adaptability: Laser welding is suitable for a variety of materials, including carbon steel, stainless steel, aluminum alloy, etc., to meet the needs of different pipe materials.

5. Environmentally friendly: Compared with traditional welding, laser welding produces less exhaust gas and noise, and is more environmentally friendly.

As the automotive industry continues to improve its requirements for product quality and production efficiency, online laser welding technology, with its unique advantages, has become the preferred technology for upgrading and transforming automotive pipeline production lines.

As a pioneer in online laser welding technology, our company has rich industry experience and technical accumulation, and is committed to providing efficient and high-quality welding solutions for automotive pipeline production.

Choose us and let us open a new chapter in automotive pipeline production together and achieve a double leap in production efficiency and product quality.

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