SmartLaser - · PDF fileNovember! 2014! Property of Comau - Duplication prohibited!...

November!2014! Property of Comau - Duplication prohibited!

November2014 Property of Comau - Duplication prohibited

EXPO LASER FORUM 2014!Piacenza "

14 Novembre 2014 "

SmartLaser ™ "


Comau in the world!

November2014 Property of Comau - Duplication prohibited

Comau in the world

Italy!

France!

Germany!

U.K.!

Poland!

Romania!

Czech Republic!

Spain!

Russia!

U.S.A.!

Mexico!

Brazil!

Argentina!

China!

India!

INNOVATION CENTER!INDUSTRIAL OPERATIONS! ENGINEERING! INNOVATION CENTER

Spain

Russia

Italy

20!

November!2014! Property of Comau - Duplication prohibited! 3!

Robot & Laser @ Comau Robotics"

1985! 1990!

2002!

2005!

C4G!

200200200 2011!

C5G!


Overview of SmartLaser™ !

welding system!

SmartLaser™: overview"


SmartLaser™ is a system for remote 3D laser welding. It consists of 4 axes with the standard dynamics and kinematics of a Comau anthropomorphous industrial robot and an optical system able to reposition the beam focussed in 3D with very high dynamics.!The new system has been developed using the Smart NJ4 robot as a base, coupled with the C5G control.!The integrated kinematic performance permits simultaneous movements between two linked ARMS, one following the other: the base of one ARM (carried) has to be joined to the terminal flange of another ARM (carrying).!In the application the carried robot is the Optical arm, the carrying robot is the SMART NJ4 reduced to 4 axes. The TCP (Tool Centre Point) that will carry out the process will be that of the carried robot.!




The two robot arms are integrated since the Cartesian position of the carried robot is calculated by the system software taking into account the geometry of the carrying arm.!!In fact, it will be possible to move the laser beam focus along a straight trajectory while the carrying arm is in motion or move the carrying arm keeping the laser focus stationary.!!The solution patented by Comau can orient the beam with an optical system having accelerations 60/70 times greater than the typical robot axes. Inside the work volume any 3D robotised form of welding can be carried out, obtaining significant optimising in the machining costs.!


SmartLaser™: Increasing of productivity"

Wel

ding

1"

Wel

ding

2"

Wel

ding

3"

Wel

ding

4"

Wel

ding

5"

Wel

ding

6"

Star

t"

End"

SmartLaser ™ welding !

Conventional laser welding ! Unproductive time of laser beam or element repositioning!

Wel

ding

1"

Repo

siti

onin

g 1"

Repo

siti

onin

g 2"

Repo

siti

onin

g 3"

Repo

siti

onin

g 4"

Repo

siti

onin

g 5"

Wel

ding

2"

Wel

ding

3"

Wel

ding

4"

Wel

ding

5"

Wel

ding

6"

Star

t"

End"

High reduction in duty cycle: elimination of downtime!!

HIGH SPEED IN LASER BEAM REPOSITIONING !& !LARGE WORKING VOLUME!


A.! C5G Control unit with Application box for SmartLaser™ !

B.! Robot SmartLaser™ !

C.! Laser generators (IPG or Trumpf)!

D.! SmartLaser™ outfitting!

E.! SmartLaser™ application software !

SmartLaser™: configuration of the system"

C

HW connection"

Optical fiber"

Field bus"

Robot: controller connection"

AB

E

D


SmartLaser™: structure of the robot"

SmartLaser™ can be divided into two fundamental assemblies: ! ARM 1: 4-axis robot obtained from the Comau SMART NJ4" ARM 2: Optical arm to orient and focalize the laser beam!!Moreover, the ARM 2 is divided into two distinct parts:!Collimation and zoom assembly: the focal distance is treated as a linear axis. This linear axis is an electronic cam controlled by three motor-driven axes that adjust the distance between the lens packs: the axis with the longest range is the master axis, whereas the other two are slave axes; each of the three axes is a non linear function to the focal distance and as such its expression is obtained by spline interpolation starting from a predefined number of significant points, determined by means of an identification process.!Scanning head: the kinematics can be likened to the kinematics of a polar robot where the two rotating axes control the orientation of the laser beam.!

!


The focal distance is managed as a linear axis. This axis is a electronic cam with three driving axes for the lenses moving. !The bigger axis is the master axis the other are slave; each axis is a non linear function of focal distance calculated by a spline interpolation with a defined number of samples.!

3 Lens axis:!Max speed 4m/s!Acceleration 80 m/s2!

function of focal distance calculated by a spline interpolation with a defined number of samples.

The focal distance is controlled by 3 motors but the programmer ‘sees’ only one axis.!

SmartLaser™: collimation and zoom assembly"


Axis 5 - mirror (+10°, -7,5°):!Max speed 22 rad/s!Acceleration 150 rad/s2!

Fixed mirror (45°)!

Lenses for focalization!

Mirror with two axis to orientating the laser beam!

SmartLaser™ : Scanning head"

Axis 4 - mirror (+/- 140 °):!Max speed 30 rad/s!Acceleration 250 rad/s2!


Visualization of J3 Master E-Cam Axis:"•! Red: laser power!

•! Blue: laser pointer!

Visualization of scanning mirror:"•! J4: joint position for axis 4!•! J5: joint position for axis 5!Active focal joint position values"

Buttons for:"•! Focal selection!

•! E-Cam enabling!•! Arms linking/unlinking "

TCP position"

Dedicated interface for Laser system management"

SmartLaser™: motion management"


In addition to E-Cam law to define the laser power TCP (tool center point) at 1030/1070 nm (Focal power), it is possible to select from the TP4i interface focal that define the tcp for 650 nm (laser pilot)!!When is selected the Focal pointer from interface, is showed the current position of axis 3, as well as the position in which the axis should be during welding path (Focal power).!!If is selected in programming mode the Pointer focal (T1), switching in T2 or Auto or Remote automatically is activated the Power focal.!

SmartLaser™ : system software"


Axis 1! Stroke: +/-180°!Speed: 110°/s!

Axis 2" Stroke: -75°/+95°!Speed: 110°/s!

Axis 3" Stroke: -10°/-230°!Speed: 110°/s!

Axis 4!!

Stroke +/- 200°!Speed: 180°/s! 1"

2"

3"4"

SmartLaser™: four axes of NJ4 "


13" 24"5"

Axes 1 / 2 Slave E-Cam - linear axes!

Stroke, Speed, Acceleration:!as a function to axis 3 Master !E-Cam!

Axis 3 Master E-Cam - linear zoom axis!(The axis 3 Master E-Cam results from the law of motion of axes 1 and 2 Slave E-Cam).!

Stroke: +0.1 mm; +315.0 mm! (+0.0039 in to12.402 in)!Speed: 3 m/s!Acceleration: 45 m/s"!

Axis 4"Rotation axis (Mirror in!azimuth)!

Stroke +/- 140°!Speed: 1289°/s!Acceleration 8057 °/s2!

Axis 5"Rotation axis (Mirror in!elevation)!

Stroke: -7,5°; + 10°!Speed: 945 °/s!Acceleration: 4834 °/s2!

SmartLaser™: optical arm"


Laser generator"The SmartLaser™ is designed for integration with a laser generator having these characteristics:! beam spread at exit from optical fiber # 110 mrad! diameter of optical fiber: 200 $m! laser power up to 5000 W! laser wavelength % = 1030 nm or 1070 nm!!The communication with the laser generator takes place by:! Fieldbus: for I/O signals! Analog signal: to manage the laser power!!Are avalaible two di&erent type of laser generators:!Trumpf: Trudisk (optic fibre attachment: Trumpf type LLK-D)!IPG: YLR series (optic fibre attachment: Optoskand type QD)!!

SmartLaser™: laser generator"


Fiat project: Cassino"

Customer: Fiat Group Automobiles"Plant: Cassino"

Welding of rear and front door of Lancia Delta e Alfa Romeo Giulietta"4 SmartLaser: 2 for dimples, 2 for welding "


Dimples: "Number of dimple for each stitch = 2 !

Total number of dimples = 104!Total Cycle time = 12 s!

Welding: "Lenght of each stitch = 20 mm!

Total number of dimples = 52!Total lenght of welding = 1040 mm!

Total Cycle time = 25 s!

Welding rear door Lancia Delta!

Fiat project: Cassino"


Fiat project: Fiasa"

Customer: Fiat Group Automobiles"Plant: Fiasa, Belo Horizonte"

Welding of rear and front door of Fiat Bravo"1 SmartLaser for welding "


FAS project: Kragujevac"

Customer: Fiat Group Automobiles"Plant: FAS Kragujevac (Serbia)"

Welding of rear and front door of 500 L"4 SmartLaser: 2 for dimples, 2 for welding "


Dimples: "Number of dimple for each stitch = 2/4 !

Total number of dimples = 138!Total Cycle time = 16 s!

Welding: "Lenght of each stitch = 20 mm!

Total number of weldings = 46!Total lenght of welding = 920 mm!

Total Cycle time = 23 s!

Welding front door Fiat 500L!

FAS project: Kragujevac"


GAC project: Changsha"

Customer: FGA&GAC"Plant: Changsha (China)"

Welding of rear, front door and decklid of Fiat Viaggio"5 SmartLaser: 2 for dimples, 3 for welding "


FGA project: Melfi"

Customer: FGA"Plant: Melfi ( Italy )"

Welding of rear, front door of Fiat 500 X and Jeep Renegade"3 SmartLaser: 1 for dimples, 2 for welding "


Fiasa project: Pernambuco"

Customer: FGA"Plant: Pernanbuco ( Brazil )"

Welding of rear, front door of Fiat 500 X and Jeep Renegade"3 SmartLaser: 1 for dimples, 2 for welding "


GAC project: Changsha"Customer: FGA&GAC"

Plant: Changsha (China)"

Welding of rear, front door of Fiat 5ooX and Jeep Renegade"4 SmartLaser: 2 for dimples, 2 for welding "


Tofas project: Bursa"Customer: FGA&Tofas"Plant: Bursa ( Turkey )"

Welding of rear, front door of New Models"4 SmartLaser: 2 for dimples, 2 for welding "

??? "

June!2013! Property of Comau - Duplication prohibited!

Via Rivalta, 30!10095 GRUGLIASCO (TO)!

ITALY!

www.comau.com!

Property of Comau - Duplication prohibited!

Via Rivalta, 30!10095 GRUGLIASCO (TO)!

ITALY!

COMAU S.p.A."

SmartLaser - · PDF fileNovember! 2014! Property of Comau - Duplication prohibited!...

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