Simulation has traditionally been used across all stages of design, from early capital expenditure (capex) planning to production routing optimization. That’s still the case today, but simulation models have recently made their way into production planning processes. “We take a simulation model of our production environment and run the order forecast through a few scenarios to make better decisions around worker allocation, WIP [work in progress] strategies and quantities, and even planned downtime for equipment,” says Michael Sarvo, digital design business development manager for Rockwell Automation. “This is a winning strategy because you can improve your reaction time to constantly changing conditions.”

Simulation differentiates the early adopters from the laggards within various segments and industries, says Iiro Esko, industry manager and digital transformation architect for Siemens Digital Industries. “You use simulation through optimization, training, commissioning, acceptance testing, engineering, and in connection with procurement and sustainability planning,” he says.

The State of Simulation

While some top-level manufacturers understand the benefits that simulation software offers, not everybody is on board yet. “There’s a massive spectrum of adoption and tech level out there,” Sarvo says. “Some companies are all in and have made simulation and related practices an integral part of how they do business, while others still don’t see how this kind of technology could possibly be a benefit.”

There are many different types of simulation software, as well as different ways to classify it, notes Ravi Aglave, director for chemical and process industry at Siemens. Control simulation, for example, relates to how you can achieve control of any given process. Molecular-scale simulation illustrates how materials will behave at a molecular level. Structural simulation provides insights into how the structure of a building or a car or an airplane might behave or respond.

Simulation can be defined by its scale — anywhere from molecular to the whole plant — or by the depth of understanding it provides. Before considering simulation software, manufacturers first need to understand what they want to get out of it. Is it to optimize costs, quality, or system operation, or to increase profitability? Simulation in automation addresses all of the above: It reduces costs by minimizing trial and error in physical setups, enhances flexibility by allowing rapid adjustments to system designs, and improves product quality through refined control over manufacturing processes.

Sarvo explains the benefits simply: “Simulation tools provide a more efficient and more accurate means of predicting the future. When you have better and earlier predictions, you have more opportunity to plan, design, and execute, resulting in better outcomes.”

At Rockwell Automation’s Emulate3D User Group Meeting in October, integrator Automation Intelligence explained how it used simulation software to help the second largest distributor of beer, wine, and spirits understand whether it could add 20% new volume without constructing another building.

Republic National Distributing Company (RNDC) handles more than three million cases per year at its distribution center in Morgan Hill, California. But the company faced challenges due to labor shortages, growing demand, new material handling equipment, and resource allocation within a multilevel pick module. The strategy was to replace manual processes and storage areas with high-tech automation and control systems. But such significant upgrades bring their own risks.

“Think about it — you must shut down existing production, install new, unfamiliar systems, and train engineers, operators, and maintenance personnel,” Sarvo says. RNDC used Emulate3D to model its production environment to understand how the new automation could be used to meet production demands. “Because of the way Emulate3D software works, they were also able to test and debug their new control systems against the model before the real system was built, and they were able to train their people on the new processes and equipment, so they were ready for production as soon as the new system was online.”

In production, RNDC continues to use the hybrid simulation/digital twin models to run forecast data and optimize daily production schedules.

How the Digital Twin Fits In

At its core, simulation software creates digital twins of production systems, machines, and workflows, allowing manufacturers to explore a wide range of scenarios without the cost and risk of real-world experimentation.

For Siemens, a digital twin is the digital representation of theoretically all different types of simulation, says Andrea Sassetti, innovation manager, Siemens Digital Enterprise Lab at MxD. “We are able to cover many different aspects — molecular fluid dynamics, mechanic, kinematic — and also simulate a sensor and see how it performs in a digital space,” he explains. “All those types of things are possible using simulation tools that are capable of converting the simulated activity for the behavior of standard equipment or device or valve or motor in a digital point of view.”

In partnership with the U.S. Department of Defense, MxD in Chicago is an ecosystem designed to solve critical manufacturing challenges. There, the Siemens Digital Enterprise Lab provides a live mock manufacturing environment to demonstrate Industry 4.0 technologies with the merging of virtual and physical worlds.

At MxD, Siemens partnered with collaborative robot (cobot) manufacturer Universal Robots (UR) to create a palletizing cell, for example, to simulate the robot. “We are able to simulate all the behavior of the equipment — pick the parts, drop on the pallet, open and close the gripper, and do many cycles based on position,” Sassetti says. “All these types of things can be done before purchasing the hardware, including the metal, the PLC, and the end effector.”

The UR simulations are also concerned with safety, Sassetti adds. They can simulate what the cobot will do when next to a human operator and determine where in the process it’s necessary to slow down or even activate the emergency stop.

Hirata, a Japanese system manufacturer that supplies transmission and engine assembly lines and electric vehicle and other automotive production equipment to numerous manufacturers, uses Siemens’ Process Simulate as part of a broad digital transformation initiative. With it, the company has been able to shorten the time it takes to go from product design to manufacturing.

Previously, Hirata required three engineers working 3–10 days to complete equipment validation. Using Process Simulate for 3D model validation, Hirata has reduced workforce hours by 90% and human-hour requirements by 66%.

Hirata has also used digital simulation tools to teach its robots offline. “Previously, we had to turn on the power, start up the robots, and then perform the teaching work to check for interferences, cable twists, and other issues,” says Shoichiro Seki, general manager of the engineering departments at Hirata. “Now all of that can be performed offline, which is incredibly helpful for manufacturing.”

Offline Robot Programming

As a subsector of simulation software, offline robot programming (OLRP) can greatly benefit how integrators and manufacturers program, deploy, and reprogram their robots by eliminating the need to interrupt productivity.

Octopuz, which focuses specifically on the OLRP sector, says the software is just finding its footing in the general manufacturing market. As opposed to factory simulation software, which simulates how parts move through production, for example, and figures out bottlenecks, OLRP takes a much more focused view by creating production code that can be used in the real world.

The top application for Octopuz’ OLRP offering is robotic welding. “Rather than programming the robot by standing in front of it with a teach pendant to do all the things needed to do a weld, you’re going to use software like Octopuz to do all that programming in a virtual environment,” says James Schnarr, senior product manager at Octopuz. “[Users] can make sure that the program is free of errors — so the robot’s not going to have errors and there’s not going to be any collisions. And then we actually produce the robot code at the end of it. They bring it to their robot, and it’s ready to run exactly as they expected it to based on what they designed in our software.”

A key benefit to using OLRP as opposed to a teach pendant is to eliminate robot downtime. Typically, a user programs a robot to do one task. If the job changes, the time it takes to program the robot for a new task or product is time that the robot is not working.

That’s in part why robotic welding is a particularly important OLRP application. In robotic welding, changing one part can mean reprogramming 100 different welds. “If I’m standing in front of the robot with the teach pendant, I’m doing two things: I’m taking a long time to program those 100 welds, as I manually jog the robot through each of those welds and do the programming, but I’m also taking the robot off production,” Schnarr says. “That might take a day, it might take five days, it might take three weeks, depending on the complexity of the welds and of the programming. And if my robot’s getting programmed, then it’s not running production.”

Conversely, with OLRP, the robot can be performing its initial weld job while the software is running on the computer. When the manufacturer is ready for the robot to move to the next job, the code is ready as well. “I might do some touch-ups, but I’m going to be ready to go with production in a few hours, maybe a day, as opposed to multiple days or weeks,” Schnarr says.

Aside from welding, applications that benefit from simulation software are other high-mix, low-volume operations, such as a fab shop performing contract work for several different customers.

Jomar Machining & Fabricating in Middlebury, Indiana, manufactures tire shredding equipment used for recycling tires. The company employs robots for hardfacing — the type of welds that most humans don’t like to do, says Lyndon Schlabach, robot programmer for Jomar, who also oversees the company’s welding operations.

“We had one robot that I was programming before we bought Octopuz. We were stopping the robot for a week straight just to do programming on a part,” Schlabach says. “With Octopuz, we can program the robots while they’re in production.”

Jomar has also found that the robots programmed offline produce better-quality welds. “On a surface weld, like we’re doing, to try to manually program all these paths and make them so they line up correctly to get a good even weld, it took a lot of time,” Schlabach says, adding that parts made by the Octopuz-programmed robots last longer in the field.

Artificial Intelligence and the Industrial Metaverse

Simulation continues to evolve. “Today, the kind of simulation that you can run is probably a trillion times what you could do maybe 10 or 15 or 20 years ago,” Aglave says. “There are two parallel advances that are happening. One is the computing power itself, and the other is the understanding of the behavior of objects and systems — the physics behind it.”

As with many other manufacturing technologies, artificial intelligence (AI) is likely to speed the progress of simulation capabilities. “It only makes sense that we’ll see artificial intelligence integrations of all kinds,” Sarvo says. “People are certainly using AI decision-making algorithms. There are APIs [application programming interfaces] for that sort of thing, and powerful simulation tools provide open scripting environments where users can extend the software’s functionality as they like.”

AI is also gaining momentum to create simulations that are a hybrid between physics- and data-based models. “The second thing that will be gaining momentum would essentially be how to take a large simulation and reduce it down into a simpler behavioral model for controlling the manufacturing operations,” Aglave says, referring to this as an executable digital twin. “The simulation essentially acts as a distilled, intelligent brain that can be used to ask questions and immediately get answers to make changes to the manufacturing operations.”

Combining AI with digital twins creates an industrial metaverse. “The next level of the digital twin is the industrial metaverse because it’s a place where we are leveraging the real data in combination with the digital twin, as well as the AI that is running behind the scenes in order to validate what is happening in the plant,” Sassetti explains. “It’s a live environment where you are able to test new possible solution improvements.”

By: Aaron Hand, TECH B2B, A3 Contributing Editor

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The Evolution of Machine Vision

Historically, machine vision systems were built for controlled environments where consistent lighting and predictable object placement were crucial. As manufacturing environments evolved, these systems struggled to keep up with more complex requirements. AI has reshaped this landscape by allowing machine vision to analyze and interpret nuanced visual data, detecting subtle patterns and defects with remarkable accuracy. Today, machine vision AI systems are capable of learning from vast datasets, adapting in real time, and continuously improving their performance.

One of the most significant advancements is the shift toward edge computing, where data processing happens directly on the production floor rather than in a centralized data center. This setup reduces latency, enabling real-time decision-making for applications like quality control, defect detection, assembly verification, and packaging.

Key Components of Effective Edge Hardware

Implementing a successful AI-based machine vision system requires the right combination of software and hardware. Selecting the appropriate edge hardware is critical, as it serves as the backbone for running AI models and processing large volumes of visual data at high speeds. Here are some key hardware requirements for effective machine vision integration:

• Compute Power and Memory: AI models used in machine vision are data-intensive and require substantial computing power. Hardware equipped with modern CPUs and GPUs, as well as high-bandwidth memory, is essential to support these demands.
• I/O Support: Machine vision systems typically require connections to various cameras and networked devices. Edge hardware should support diverse interfaces to facilitate seamless integration.
• Environmental Protection: Industrial environments can be harsh, with exposure to dust, moisture, and temperature fluctuations. The selected hardware should be rugged enough to withstand these conditions.
• Expansion and Customization: As machine vision applications evolve, the ability to expand and customize hardware becomes increasingly important. Flexible hardware solutions enable manufacturers to scale their machine vision capabilities without extensive reconfiguration.

Scaling Machine Vision with Axiomtek’s IPC962A

One example of cutting-edge edge hardware designed for AI-enhanced machine vision is Axiomtek’s IPC962A, an industrial-grade computer that embodies the necessary robustness, power, and flexibility for these applications. Engineered with the specific requirements of AI in mind, the IPC962A provides manufacturers with a scalable and adaptable solution. Key features of the IPC962A include:

• High-Performance CPUs and GPUs: The IPC962A is equipped with advanced processors capable of handling complex AI algorithms, facilitating fast and accurate image processing.
• Comprehensive Connectivity Options: With multiple I/O ports, this system easily connects to various types of cameras and other devices, supporting extensive machine vision configurations.
• Multiple Display Capabilities: For high-resolution machine vision applications, the IPC962A supports multiple display outputs, allowing operators to monitor and control processes in real-time.
• PoE (Power over Ethernet) Management: The device supports PoE, enabling the connection of cameras and sensors that rely on power through Ethernet cables, simplifying setup and reducing the need for additional wiring.

The IPC962A’s versatility makes it ideal for a wide range of machine vision applications, from defect inspection in high-speed assembly lines to the verification of assembled components. With this solution, manufacturers can leverage the power of AI to achieve a higher level of quality control and operational efficiency.

The Benefits of AI-Driven Machine Vision

By integrating AI at the edge, machine vision systems become highly efficient tools for quality assurance, capable of delivering unprecedented accuracy and speed. The benefits are wide-reaching:

• Enhanced Accuracy: AI-driven machine vision detects minute defects that traditional methods might miss, ensuring consistently high-quality output.
• Reduced Downtime: Real-time processing at the edge allows for instant feedback, reducing downtime by identifying issues before they escalate.
• Improved Traceability: With advanced data collection and analysis capabilities, machine vision systems enable comprehensive tracking and traceability of products, aiding in quality assurance and regulatory compliance.
• Scalability: Edge-based AI systems can grow with the organization, adapting to new products, workflows, and market demands.

Axiomtek: Partnering for Future-Ready Solutions

Axiomtek’s machine vision solutions are designed to meet the challenges of modern manufacturing, supporting Industry 4.0 and smart manufacturing initiatives. With the IPC962A and other offerings, Axiomtek provides a comprehensive solution for manufacturers looking to embrace AI at the edge. Their commitment to customization and customer support ensures that manufacturers can effectively integrate these advanced systems, enabling them to optimize processes and improve productivity across the board.

By combining AI-driven machine vision with powerful edge hardware, Axiomtek is helping manufacturers realize the full potential of Industry 4.0, paving the way for a new era of precision, efficiency, and adaptability in industrial automation.

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Facts Over Feelings

The discussion around sustainability is emotionally charged, but at Fronius, our approach to sustainability centers on the evidence. We start by bringing the facts to the table: “We examined two typical, real-world applications that our customers use when welding steel and aluminum, and had the analysis certified by the highly regarded Fraunhofer Institute,” explains David Schönmayr, Team Leader for Product Sustainability at Fronius International GmbH. Fronius experts, together with partner to4to (together for tomorrow), meticulously assessed the environmental effects of the welding variables, such as material, energy, gas, and emissions using standardized methods as part of a life cycle analysis. Based on this, we can get a detailed picture of a welding machine—in this case the TPS/i 320 and TPS/i 400. This comprehensive “cradle-to-grave” approach starts with the procurement of the raw materials, includes the production of the welding machines and transport, as well as years of use in industrial shifts, including wear parts, and also examines what happens when the welding machine has reached the end of its life cycle after a long service life.

Translating the Carbon Footprint to 1 Meter of Weld

Every component and every welding application is individual and influenced by many factors, such as the base material, the seam geometry, and the welding parameters used. That’s why Fronius chose a framework that allows the results to be presented clearly so they’re easy to understand. “We translate the CO2 proportion of the relevant parameters over to 1 meter of weld, because it quickly shows us where our starting point should be,” Schönmayr explains. “For the CO2 proportion in use, we’ve based our calculations on the welds of robot series production with a typical duty cycle of eight years. We did this by referring to actual customer examples, which consisted of an automotive supplier that uses the TPS 400i in its robot configuration for steel welding and a vehicle manufacturer that welds with the TPS 320i CMT.”

The Biggest Lever: Resource-Efficient Use

In the life cycle of a Fronius TPS/i welding system, only around 0.5% of the total CO2 equivalents comes down to the production, repair, and disposal of the welding machine. The rest is split between the filler metal, the shielding gas, and the energy consumed, which highlights the importance of making efficient use of these resources in particular.

“The good news is that at Fronius we have already been working for many years to keep our material and energy consumption during welding as low as possible. To this end, we have built up almost 75 years of know-how and developed innovative—and sometimes groundbreaking—technologies such as the first inverter welding machines (Transarc 500), the first digitally process-controlled TPS welding systems, and the revolutionary CMT (Cold Metal Transfer) welding process. When it comes to efficiency, we believe that digitalization continues to present tremendous potential,” affirms Scherleitner. By using the WeldCube Premium welding data management and analysis tool, many Fronius customers have already succeeded in optimizing their production—and thanks to the high quality of the results, they are now boosting their time and material savings as well.

Economic Benefits = Environmental Benefits

Fronius wants to work together with its customers to tackle areas where CO2 can be reduced. High welding quality plays a central role here to ensure the materials are used as efficiently as possible, or in other words by avoiding wasting resources with rejects or rework. Reproducible, high-quality welded joints protect both the bottom line and the environment, which is why taking a holistic view of production at component level (TCOP—total cost of production) can have a huge impact. However, Fronius also has solutions that are very easy to implement, such as the OPT/i Gas digital gas controller, which can reduce shielding gas use by an average of 40%. If there are lots of short welds, the savings potential is even higher.

“Sustainability in joining is at the top of our agenda. Our experts in research and development follow the ‘Sustainability by Design’ approach. In this way, we create environmentally inspired innovations combined with our understanding of the challenges faced by our customers. However, the best way to save material, time, and money while gradually reducing the carbon footprint is by working together. Our LCA is only the starting point for a series of tips that we’ll be sharing with our customers,” summarizes Scherleitner.

The experts at Fronius can provide targeted support to help customers identify carbon savings potential in production, for example by using the OPT/i Gas digital gas controller or the WeldCube Premium monitoring and analysis tool.

The post Focusing on Carbon Footprint for More Sustainable Welding appeared first on IndMacDig | Industrial Machinery Digest.

Micro Arc Joining Under the Hood

Micro TIG is an arc welding process that creates a high temperature (5000°C) plasma arc between a tungsten electrode and the workpiece. An inert gas (typically argon) helps plasma arc generation by displacing air from the weld area, thus lowering the resistance or voltage requirement to jump across the gap. The technology is geared toward weld areas that are less than 18mm², for example, a copper busbar, and reaching spots as small as 0.14mm², such as thermocouple wires. This is achieved by supplying a lower current for shorter times with more precise control.

Micro TIG welders typically supply a current from 5 to 300 Amps with pulse durations of up to 999ms. Sometimes the pulse is divided into multiple pulses by rapidly turning the current on and off. This feature, called “current modulation,” reduces the porosity of the completed weld nugget. By heating metal material through the arc formation, Micro TIG welding causes materials to melt and fuse together. The best results come from joining two pieces of the same metal of similar size. However, it is also possible to weld dissimilar metals.

Which Materials?

Good materials for Micro TIG Welding include copper, phosphor bronze, iron, nickel, stainless steel, molybdenum, tungsten, platinum, and titanium. Brass and galvanized steel are not considered appropriate for Micro TIG welding because their zinc content causes welding issues such as porosity and soot contamination. Applications of pulsed Micro TIG Welding include battery tab welding and coil wire welding.

Micro TIG Welding Technologies

Different Micro Arc Joining technologies are suitable for different applications and/or process requirements. The three most common use a touch-start mechanism, high-voltage start mechanism, or a percussive process.

Touch-Start

If a touch-start mechanism is used, the electrode comes down to touch the workpiece and then retracts, causing an arc to be generated. The weld area is generally protected from atmospheric contamination by the use of an inert shielding or cover gas (argon or helium).

High-Voltage Start

With a high-voltage start mechanism, the standoff between electrode and workpiece is set at a fixed distance. The start arc must then overcome the breakdown of air to bridge the gap.

Percussive Arc Welding

Percussive Arc Welding combines Micro Arc TIG welding with a mechanical “percussive” movement that forces the arcing components together. The heat from the arc creates two molten interfaces which, when pushed together, fuse as a weld and extinguish the arc, forming a butt weld. The process is very quick and controllable, requiring high-speed real-time control elements and a degree of programmable flexibility to deliver a manufacturing standard system. It is widely used for butt welding of thin wires, stranded wire to pin joining, and blind thermocouple welding.

Application Examples

Examples of Micro TIG Welding used for typical coil to pin termination and E-mobility applications are shown in Figure 2.

Hairpin Joining

One of the most common applications is hairpin joining, which is being used more and more as manufacturers seek to build smaller, lighter, more powerful electric motors that improve electro-conductivity.

With Micro TIG Welding, accessibility to the weld joint is from the top of the hairpins, making it a good process to consider when there are space constraints. Alignment of the pins is key to getting a good weld. The pins and torch need to be precisely aligned such that the center of the torch is positioned in the middle of the pins. Tooling is required to achieve precise and repeatable alignment; this will result in symmetrical weld geometries.

Micro TIG Welding Equipment Selection

Equipment selection is key to successful Micro TIG Welding. One option is AMADA WELD TECH’s Touch Retract System, which includes the TR-T0016A Touch Retract Micro Arc Torch paired with the PA-T0200A Power Supply.

The Touch Retract Micro Arc Torch works like a hand-held tool, allowing staff to use the torch after a short training to rapidly assemble prototype technologies such as battery packs.

The welding process proceeds in three steps:

• Approach: The electrode extends below the nozzle, enabling the operator to see where they are placing the weld.
• Compression: During the compression step, the operator pushes down on the torch. A small current detects that the electrode is in contact with the workpiece.
• Retraction: In the final retraction phase, the electrode retracts, drawing an arc with an intermediate current. When the mechanism is at full travel, the main welding current is applied.

The torch offers a machine mounting collar for integration into automated solutions. A 7mm nozzle and protruding electrode lead to easy location of the weld area, and it includes an integral ground contact for arc operation and welding gas discharge port. There is no user contact with components at high voltage and no direct exposure to artificial optical radiation. For scaling up production, the TR-T0016A Torch can be mounted on automated production solutions for uniform and high-speed production.

The high degree of control offered by the PA-T Power Supply enables the resultant spot welds to be size-optimized while minimizing battery can heat penetration. The power supply includes an intuitive color touch screen, I/O configuration and calibration screens, a built-in weld counter, and a graph of voltage for the last weld and energy trend against time. It is fully programmable with upslope, peak, and downslope. Current modulation allows the user to selectively turn the current on and off during the weld. This results in controlled heat input to the part, eliminates internal porosity and external dimples, and makes the weld size and shape uniform.

For example, a typical 0.3mm copper strip to 18650 battery can application will require a weld profile as shown in Figure 6. The Touch Retract system has a duty cycle rating of 5 percent at 100A. For a weld with the profile shown, this equates to a maximum work rate of a single 50ms pulse of 100A per second or a weld about every 1.3 seconds.

For percussive arc welding for on-axis stranded wire to pin terminations, a good power option is the Percussive Arc Power Supply PA-P200A. This 200-amp percussive arc linear TIG welding power supply incorporates power electronics interfacing and software to facilitate highly controlled percussive arc processes to be performed with a high degree of process control, monitoring, and checking.

Summary

For EV manufacturers looking for mechanically robust and electrically conductive joints, Micro TIG Welding can be an excellent choice, particularly for battery cell/busbar assembly, sensor joining, and connector joining, as well as automobile coil, busbar, solenoid harness, and sensor applications.

By Richard Barber, AMADA WELD TECH Europe

About AMADA WELD TECH

AMADA WELD TECH is a leading manufacturer of equipment and systems for Laser Welding, Laser Marking, Laser Cutting, Resistance Welding, Hermetic Sealing, and Hot Bar Reflow Soldering & Bonding. We design and manufacture industry-leading product families for the global market and customize our products around specific micro-joining applications. AMADA WELD TECH’s key markets include medical devices, battery, automotive, solar industry, electronic components, and aerospace. AMADA WELD TECH Europe is headquartered in Germany and has additional production facilities in The Netherlands and UK, as well as sales offices in France, Hungary, and Italy. The company is part of the global AMADA Group, with over 8,500 employees worldwide. More information on products and services can be found at https://www.amadaweldtech.eu.

The post Micro Arc Joining for Electric Vehicle & Battery Applications appeared first on IndMacDig | Industrial Machinery Digest.

Understanding ASRS Technology

Automated Storage and Retrieval Systems are sophisticated, high-density warehouse solutions designed to automate the handling of inventory. These systems consist of several key components, including storage racks, retrieval machines (such as cranes or shuttles), and a warehouse control system. There are various types of ASRS, each suited to different warehouse requirements and product sizes:

• Unit-Load ASRS: Designed for handling large items or pallet-sized loads.
• Mini-Load ASRS: Suitable for smaller items, typically stored in totes or bins.
• Micro-Load ASRS: Used for handling very small items, often integrated into parts-picking operations.
• Carousel-Based ASRS: Utilizes rotating shelves to deliver items to a picking station.

The integration of advanced robotics, sensors, and control software allows these systems to operate with minimal human intervention, ensuring precision and reliability in inventory handling.

Role of ASRS in JIT Inventory Management

The implementation of ASRS is crucial for the effective execution of JIT inventory management in manufacturing warehouses. By automating the storage and retrieval processes, ASRS ensures that materials are available exactly when needed, thus synchronizing seamlessly with production schedules. This real-time capability eliminates delays and reduces the necessity for large inventory buffers, which is a fundamental aspect of JIT principles. ASRS can swiftly and accurately store incoming materials and retrieve them for production, maintaining a continuous flow of inventory that supports ongoing manufacturing processes.

Benefits of Using ASRS for JIT Management

The adoption of ASRS within JIT inventory management brings several substantial benefits:

• Increased Efficiency and Reduced Lead Times: ASRS systems significantly speed up storage and retrieval processes, thereby reducing lead times and ensuring materials are available for production without delay.
• Minimization of Inventory Holding Costs: By closely aligning inventory levels with production needs, ASRS helps minimize costs associated with holding excess inventory, such as storage costs, insurance, and obsolescence.
• Enhanced Accuracy in Inventory Tracking and Movement: ASRS provides precise tracking of inventory locations and movements, reducing errors and ensuring the right materials are available at the right time.
• Flexibility in Adapting to Changing Production Demands: ASRS can be easily reconfigured to adapt to changing production schedules and inventory requirements, providing the flexibility needed in dynamic manufacturing environments.
• Reduction in Labor Costs and Human Error: Automation reduces reliance on manual labor for storage and retrieval tasks, lowering labor costs and minimizing the risk of human errors.

Implementation Challenges

Despite its advantages, implementing ASRS in JIT inventory management does present certain challenges:

• High Initial Investment and Cost Considerations: The initial cost of purchasing and installing ASRS can be substantial, requiring careful financial planning and justification.
• Integration with Existing Warehouse Management and ERP Systems: Successful implementation requires seamless integration with existing warehouse management systems (WMS) and enterprise resource planning (ERP) systems to ensure smooth operations.
• Training and Adaptation of Workforce: Employees need to be trained to work with the new automated systems, which can involve a learning curve and adaptation period.
• Maintenance and Operational Downtime: Regular maintenance is crucial to keep ASRS running smoothly, and any downtime can disrupt the JIT inventory flow, impacting production.

Technological Innovations Enhancing ASRS

Ongoing technological advancements continue to enhance the capabilities of ASRS, making them even more valuable for JIT inventory management:

• Advances in Robotics and Automation: Improvements in robotic technology and automation have increased the speed, precision, and reliability of ASRS, enabling faster and more accurate inventory handling.
• Integration with IoT and Real-Time Data Analytics: The integration of Internet of Things (IoT) devices and real-time data analytics allows for better monitoring, control, and optimization of ASRS operations, improving efficiency and reducing downtime.
• Development of More Robust and Scalable Systems: New ASRS designs are more robust and scalable, allowing them to handle a wider range of products and adapt to growing warehouse needs.
• Use of AI and Machine Learning for Predictive Maintenance and Optimization: AI and machine learning algorithms are being used to predict maintenance needs and optimize ASRS performance, reducing downtime and extending the lifespan of the systems.

Case Studies of ASRS in JIT Inventory Management

In a global marketplace where efficiency and precision are paramount, many manufacturing companies have successfully implemented ASRS to enhance their JIT inventory management processes. While we won’t dive into specific case studies, it’s worth noting that companies across various sectors, including automotive, electronics, and consumer goods, have reported significant improvements in operational efficiency, cost savings, and product quality through the integration of ASRS. These real-world applications underscore the transformative potential of ASRS in modern warehouse and supply chain management.

Future Trends and Outlook

The future of ASRS in JIT inventory management looks promising, with several trends and innovations on the horizon:

• Emerging Technologies in ASRS Development: Continued advancements in robotics, AI, and IoT are expected to further enhance the capabilities and efficiency of ASRS, making them even more integral to JIT inventory management.
• Potential for Increased Adoption in Various Industries: As the benefits of ASRS become more widely recognized, their adoption is likely to increase across a variety of industries, from manufacturing to retail and logistics.
• Impact of ASRS on the Future of Warehouse and Supply Chain Management: ASRS is set to play a key role in the evolution of warehouse and supply chain management, driving greater efficiency, accuracy, and responsiveness in inventory management.
• Development of Modular and Flexible ASRS Solutions: Future ASRS designs may focus on modularity and flexibility, allowing for easier customization and scalability to meet the specific needs of different warehouses and inventory types.
• Integration with Advanced Data Analytics and AI: The integration of advanced data analytics and AI technologies will enable more sophisticated inventory management strategies, including predictive analytics for demand forecasting and real-time optimization of storage and retrieval operations.

Conclusion

The integration of Automated Storage and Retrieval Systems (ASRS) with Just-in-Time (JIT) inventory management offers a powerful solution for manufacturing warehouses. By automating the storage and retrieval processes, ASRS ensures timely, accurate, and efficient inventory handling, aligning perfectly with JIT principles. Despite the challenges involved in implementation, the benefits of increased efficiency, reduced costs, enhanced accuracy, and greater flexibility make ASRS an invaluable tool for modern warehouse and supply chain management. As technological advancements continue to enhance the capabilities of ASRS, their role in JIT inventory management is set to grow, driving further improvements in operational efficiency and productivity.

The evolving landscape of warehouse automation, bolstered by innovations in robotics, AI, and IoT, promises a future where ASRS not only supports but revolutionizes the principles of JIT inventory management. As industries continue to seek greater efficiency and cost-effectiveness, the adoption of ASRS will likely become more widespread, heralding a new era of precision and agility in inventory management. By embracing these technologies, manufacturing warehouses can achieve a competitive edge, ensuring they are well-positioned to meet the demands of a fast-paced, dynamic market.

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Supporting Customers Throughout the Product Life Cycle

Fronius provides comprehensive support from planning, engineering, manufacturing, and commissioning to the maintenance and servicing of overlay welding systems. All systems comply with international standards, ensuring safety and reliability. Technical commissioning by Fronius experts and preliminary acceptance by buyers, particularly from the oil and gas industry, take place at the production site in Steinhaus, Austria. The systems are then delivered, installed on-site, and accepted by international customers in the onshore and offshore sectors, including those in America. Fronius’ comprehensive commissioning service includes expert training and process optimizations at the start of production, ensuring that American manufacturers can achieve peak performance and efficiency.

Realistic Welding Tests and Feasibility Studies

Every new overlay welding project at Fronius begins with feasibility studies and welding tests. Overlay welding is complex, with numerous factors influencing the result. Welding tests are conducted under realistic conditions using the same materials and environmental conditions expected during live operations. This ensures the system delivers the desired results even under harsh conditions. Anton Leithenmair, Head of Fronius Welding Automation, emphasizes the importance of realistic testing to meet customer requirements and achieve optimal welding results, a crucial aspect for maintaining high standards in American manufacturing.

Complete Solutions for the Oil and Gas Industry

With over forty years of experience, Fronius has developed application-based overlay welding systems tailored to customer needs. The Compact Cladding Cell (CCC) offers a compact, user-friendly solution for valve component cladding. The Endless Torch Rotation System (ETR) is ideal for larger, complex components, featuring an endlessly rotating welding head that enhances productivity and reduces setup times. Both systems incorporate advanced features such as 21-inch touch displays, real-time process visualization, and multi-user management, providing American manufacturers with versatile and efficient tools for various applications.

SpeedClad 2.0: Award-Winning and Efficient

SpeedClad 2.0 sets new standards in overlay welding with its high deposition rate, impressive speed, and low shielding gas consumption. It significantly improves the efficiency and cost-effectiveness of welding processes, earning the Excellence in Welding Award from the American Welding Society. The SpeedClad 2.0 process uses a 1.6 mm wire, increasing the welding speed and reducing argon gas consumption, making it an ideal choice for valve component welding in the American manufacturing industry.

Comprehensive Solutions and Future Innovations

Fronius also offers longitudinal and circumferential seam welding systems, robotic welding systems, and more. These solutions are designed to meet the diverse needs of metal processing companies. Fronius continues to innovate, with a focus on sustainability and reducing consumables. The company’s commitment to customer support and technological advancement ensures that Fronius Welding Automation remains a leader in the field, benefiting American manufacturers by providing reliable and cutting-edge technology.

Fronius will showcase these innovations at the ADIPEC trade show in Abu Dhabi from November 4-7, 2024, Hall 14, Stand 14316. The Fronius team looks forward to demonstrating their cutting-edge solutions for cladding and 3D metal printing, which are highly relevant to American manufacturers seeking to enhance their operations.

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Josep Viñolas founded Viñolas Metall in 1968 in Cornellà del Terri, Spain, and the company has been producing metal constructions for companies and private consumers ever since. Years later, his son David Viñolas joined the company and invested in new machinery and technologies for the export business and to optimize project workflows through computerization. A 4,000 m2 production site in Banyoles was recently opened to complement the existing 800 m2 assembly workshop in Cornellà del Terri. In addition, Viñolas Metall has been certified to ISO 3834-2 by the Fronius Welding Academy.

The company has a diverse range of customers from different industries, including winemaking, water treatment, swimming pool accessories, mechanical engineering, plant construction, toolmaking, power plant construction, and railway construction. Viñolas Metall is known for its innovative solutions, high quality of service, and efficient, customer-oriented project management.

Current situation and new challenges

Welding currently accounts for 70 to 80% of production times. Carbon steel, stainless steel (304, 316, duplex, and super duplex), aluminum, and COR-TEN® are the most common materials processed.

It is mainly smaller components that are joined, but also large and heavy components too. Sheet thicknesses range from 2 to 40 mm. Welding is carried out in the PA (flat position), PB (horizontal vertical position), and PC (horizontal position) positions. Out-of-position welding on vertical beams and pipes is performed in the PF (vertical up position) and PG (vertical down position) positions. The most frequently used processes are TIG and MIG/MAG for manual tasks, as well as the ArcTig keyhole welding process for automated applications. Orbital welding systems are also used, whereby the welding torch rotates around the component during joining.

As they specialize in technically demanding, complex metal structures, Viñolas Metall faced two new challenges. The first was finding a solution for creating high-quality, reproducible welds for series production where industry specifications and welding standards had to be taken into account. The components produced are exposed to high loads and used in a highly corrosive environment—for example, in plant construction.

The second requirement focused on welding autonomy and system optimization. The desired system should be able to switch between two welding processes (TIG and MIG/MAG) independently and without sacrificing the weld quality, all in the course of a quick process change.

The solution: Robotic welding cell with TPS 400i CMT

As a result of the good experiences Viñolas Metall has had with Fronius welding machines and processes, the company trusts in the professionalism and reliability of Fronius both from a technical and efficiency perspective.

“When we need to weld identical parts with the highest weld quality, we turn to Fronius, as they always have the solution we’re looking for,” says David Viñolas, managing director of Viñolas Metall.

One specific challenge for Viñolas is welding beams for swimming pool roofs from austenitic chrome-nickel steels 304 and 316. The welding solution consists of a robotic welding cell equipped with a TPS 400i CMT welding machine, a hollow arm welding robot, and a H reverser, which has two vertical turntables on a horizontal axis on both sides. Custom-made clamping devices are mounted between the turntables, each of which can accommodate four of the stainless steel beams.

Once one side of the H reverser is loaded with four steel beams, they are turned into the welding cell and joined in a single cycle. Meanwhile, on the other side, the finished welded components can be removed and four new ones positioned, saving valuable cycle time. As soon as the teaching of the system is complete, the sequence program together with axial movements is specified and the weld quality is ensured. The component handling itself can be carried out by trained operators who do not have to be experienced welding specialists—a particular advantage in times of skills shortages.

“We want our best welders to work on large projects with high added value, while smaller series parts can be welded with the robotic welding cell,” explains mechatronics engineer Matheus Borborema.

The Cold Metal Transfer (CMT) process used in the welding cell is characterized by its minimal heat input, which reduces the heat-affected zone and thus the deformation of the base material. At the same time, it impresses with its extremely high arc stability. CMT enables higher welding speeds with low spattering, minimizing uneconomical rework and costs for consumables.

Standardization with iWave Pro in robotic welding cells

Viñolas Metall has been placing its faith in Fronius since 2016, when the first TPS/i welding system for intelligent MIG/MAG welding was introduced. Recently the company has been facing a new challenge: the welding robot must weld various components using both the TIG and MIG/MAG process—with rapid process changes and programmed configurations. Welding quality and system stability must be kept constant throughout. The welding solution to meet this challenge is the iWave Pro AC/DC multiprocess welding machine from Fronius.

“The reliability of the equipment and service quality of technology partners are key factors for us,” emphasizes David Viñolas. “The Fronius support team fully supported us during the test phase of the new iWave Pro. We have now purchased four more devices.”

Viñolas plans to gradually replace all the old equipment, so that by 2025 all 15 welding cells will be equipped with the iWave Pro, and all the company’s welding machines will be Fronius devices. The main reason for purchasing the multiprocess welding machines is the fast process change. Overall, the iWave increases productivity, saves consumables, and requires less space. What’s more, production efficiency is increased because welding specialists can use the welding process immediately required—without wasting time switching between TIG and MIG/MAG.

On Viñolas Metall’s journey towards Industry 5.0, the iWave Pro stands out for its compatibility with WeldCube, the advanced Fronius welding data management and documentation software. Further advantages include the CycleTig and PMC (Pulse Multi Control) functions, which significantly contribute to the reduction in uneconomical rework. The optional DynamicWire Welding Package, enabling dynamic wirefeed during manual TIG welding, is another plus. The devices are robust and feature a long service life with low maintenance, significantly improving the ecological footprint. Their large digital color display is easy to use even with welding gloves.

From now on, Viñolas Metall’s demanding projects involving tanks and other components made of carbon steel, stainless steel, and aluminum for the aerospace, pharmaceutical, and food industries will be joined by hand with the iWave Pro AC/DC.

Benefits and opportunities

David Viñolas explains: “Fronius products are far more powerful and reliable than the devices we’ve used before. They’re robust and have been developed with the needs of welding professionals in mind. Since owning Fronius equipment, we have never had to stop production due to failures. The devices are very intuitive and easy to use, and the training offered allows us to make the most of what they can do.”

In addition, Viñolas points out: “We have been working with Fronius for many years because we trust the renowned technology company. Their sales team is very empathetic and professional. The fast, reliable, and solution-oriented service has shown us that we can rely on Fronius. We were looking for a company that would not only demonstrate to us the latest technology in welding, but also support us as we embarked on the process of technological transformation.”

Viñolas and Fronius: Past, present, and future

Since the application engineers at Viñolas Metall first tested a Fronius device and the decision was made to purchase, the business relationship has gradually grown. In the meantime, further systems have been acquired, including an ArcView camera system for visual weld pool control during robotic welding, an ArcTig keyhole welding system, and ten iWave and TPS/i welding machines.

Where the shared success story began with the introduction of a robotic welding cell, it has now moved forward thanks to the purchase of four iWave Pros.

Today, Viñolas Metall is convinced by Fronius at every level.

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Waterjet cutting is akin to carving with liquid precision. It operates on a simple principle: directing a high-pressure stream of water, often combined with an abrasive substance, through a narrow nozzle to cut material with unmatched accuracy. This technique stands out for its ability to cut without the heat-affected zones, preserving the integrity of the material being cut.

How Does Waterjet Cutting Work?

Understanding the waterjet cutting process illuminates why it’s favored for diverse applications. The journey from raw material to finished product involves several stages:

• Preparing the material: Positioning and securing the material to ensure precision cutting.
• Generating the high-pressure water stream: Water is pressurized to an intensity that can slice through materials.
• Mixing abrasive materials (when necessary): For harder materials, an abrasive substance is added to the water stream to enhance cutting power.
• Cutting the material: The high-velocity water or abrasive mixture makes its precise cut according to the design.
• Post-processing steps: Includes washing and finishing the cut edges as required.

What Are the Key Advantages of Waterjet Cutting?

The benefits of waterjet cutting are manifold, making it a preferred choice in various industries:

• Precision and versatility: It can create intricate designs and patterns on a wide range of materials.
• Cold cutting process and no heat-affected zones: This ensures the material’s properties remain unaltered.
• Ability to cut a wide range of materials: From metals to composites and beyond, waterjet can handle it all.
• Minimal material wastage: The precision cutting translates to more efficient material use and less waste.

Can Waterjet Cutting Handle Complex Cuts and Shapes?

Yes, waterjet cutting excels in producing complex geometries that other methods might struggle with. This adaptability stems from its precision and the ability to cut without introducing heat or mechanical stress, preserving the material’s original characteristics.

Why Is Waterjet Cutting Considered Environmentally Friendly?

The green credentials of waterjet cutting are significant:

• Water recyclability: The water used can often be recycled and reused.
• Absence of hazardous waste: Unlike some cutting processes, waterjet cutting does not produce harmful by-products.
• Reduced material wastage: Efficient use of materials means less waste.

What Types of Materials Can Be Cut With a Waterjet?

Waterjet cutting’s versatility is showcased in its ability to handle diverse materials:

• Metals: Including Stainless Steel, Aluminum, Brass, and more.
• Composites: Such as carbon fiber and fiberglass.
• Glass and ceramics: For intricate designs and shapes.
• Stone and tiles: Ideal for custom architectural elements.
• Plastics and polymers: Offering clean cuts without melting.
• Rubber and foam: For precise shapes and sizes.

Are There Limitations to the Thickness of Materials Waterjet Can Cut?

While waterjet cutting is remarkably versatile, the thickness it can handle varies by material type. Generally, it can cut up to several inches thick, but this capacity can be material-dependent.

Which Industries Prefer Waterjet Cutting and Why?

The adoption of waterjet cutting spans numerous sectors, each valuing its specific advantages:

• Aerospace and Aviation: For precision parts that require tight tolerances.
• Automotive: For cutting complex parts efficiently.
• Manufacturing and Fabrication: For its versatility in materials and shapes.
• Electronics: For delicate components that must avoid heat damage.
• Art and Architecture: For creating intricate designs in a variety of materials.
• Energy Sector: For cutting components used in harsh environments.

How Does Waterjet Cutting Benefit the Aerospace Industry?

In aerospace, the precision and ability to cut high-strength materials without compromising their integrity are crucial. Waterjet cutting meets these requirements, making it invaluable for creating parts with tight tolerances and complex shapes.

Why Is Waterjet Cutting Ideal for Manufacturing and Fabrication?

Its versatility and precision make waterjet cutting a go-to for manufacturers seeking to reduce material waste, ensure part accuracy, and maintain the integrity of the materials they use.

Comparing Waterjet to Other Cutting Technologies

When pitted against other cutting technologies like laser, plasma, and mechanical cutting, waterjet stands out for its versatility, precision, and material-friendly process.

Waterjet vs. Laser Cutting: Which Is More Versatile?

While laser cutting is precise and fast, it introduces heat, limiting its use with certain materials. Waterjet, with its cold-cutting advantage, can handle a broader spectrum of materials without heat damage.

Waterjet vs. Plasma Cutting: Why Choose Waterjet for Precision?

Plasma cutting is suited for metal and is faster for thick materials. However, waterjet offers superior precision, especially for complex shapes or materials where heat damage is a concern.

Key Considerations When Choosing Waterjet Cutting

Selecting waterjet cutting involves evaluating several factors:

• Material type and thickness: Assessing the compatibility and optimal cutting method.
• Cutting precision and quality requirements: Ensuring the method meets the project’s precision needs.
• Project budget and operational costs: Balancing cost-effectiveness with quality. Water jet cutting systems can have lower costs and save money with optimal waterjet software.
• Environmental and safety considerations: Prioritizing eco-friendly and safe processes.

How to Optimize Designs for Waterjet Cutting

Design optimization for waterjet involves several strategies:

• Minimizing material use with nesting techniques: Efficient layout reduces waste.
• Designing for cutting efficiency: Simplifying designs where possible to reduce cutting time and costs.
• Avoiding certain geometries that increase cutting time and costs: Streamlining designs for optimal cutting efficiency.

Safety Precautions in Waterjet Cutting Operations

Ensuring safety during waterjet operations is paramount:

• Personal protective equipment (PPE) requirements: Protecting operators from potential hazards.
• Handling high-pressure equipment: Ensuring safe operation and maintenance.
• Safe material handling practices: Avoiding injury during material loading and unloading.

Cost Considerations in Waterjet Cutting

The cost of waterjet cutter is influenced by several factors:

• Material type and thickness: Different materials and thicknesses can affect operational costs.
• Complexity of the design: More complex designs may require more time and resources.
• Quantity and size of the parts: Larger or more numerous parts may increase costs.

How to Estimate the Cost of a Waterjet Cutting Project?

Project cost estimation involves considering material costs, operational expenses, and the time required for cutting. Accurate estimations ensure projects stay within budget while achieving desired outcomes.

Future Trends in Waterjet Cutting Technology

Innovations in waterjet technology continue to enhance its capabilities, with automation and artificial intelligence playing increasing roles in optimizing cutting processes and efficiency.

Conclusion

The preference for waterjet cutting in various industries is clear. Its unparalleled precision, versatility, and eco-friendly nature make it an indispensable technology in modern manufacturing and design. As we look to the future, waterjet cutting’s role is poised to expand, driven by ongoing innovations and its ability to meet the evolving needs of industries worldwide.

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The Challenge

Langley Alloys’ saw fleet reached its limits after ten years – an expansion of capacity was not possible with the existing machines. In addition, the lack of space in the production hall prevented the acquisition of further band saws. The specialist had clear ideas about his new sawing solution: in any case, it should be possible to use carbide bands in order to achieve shorter cutting times for larger stocks of nickel alloys. With this idea, Langley Alloys approached KASTO’s UK branch in Milton Keynes to discuss possible options.

The Solution

For several years band saws of the KASTOtec AC 4, KASTOwin A 4.6 and KASTOwin pro AC 5.6, have been processing their difficult-to-cut metals. Langley Alloys were able to significantly increase the cutting capacity and precision – without complex monitoring.

Thanks to the improved CNC control of the KASTO machines, the employees can set up the different sawing jobs faster, utilising the machines to correctly set the speed and feed for each job, not having to rely on the operator’s knowledge – this opens up a greater potential for operator selection!

The KASTO saws handle all sawing jobs at Langley Alloys with very little down-time. If there are any problems, the KASTO Ltd. Service Team are always quickly on-site to service or maintain them. Since the purchase of the very first KASTO saw 6 years ago, the metal specialist have 8 KASTO machines in daily use across their UK sites – Very soon to be expanded!

The Conclusion

“KASTO’s band saws are ideal for cutting our difficult materials. Here we wanted to become more efficient, and we have succeeded with the new acquisitions,” Managing Director Rodney Rice explains the decision.

About KASTO

The KASTO Group, located in Achern in Baden, Germany, (KASTO Maschinenbau GmbH & Co. KG) specialises in sawing, storage, and automation technology for metal bar stock. The company is the world market and technology leader for metal sawing machines, semi-automatic and automatic storage systems for metal bar stock and sheet metal, automated handling equipment for metal bars, sheets, and cut-pieces including the necessary, intelligent software. With 180 years of experience, KASTO is one of the oldest family-owned businesses in Europe. 170 patents, more than 140,000 sawing machines sold across the globe, and over 2,300 installed automated storage systems are a reflection of the company’s success. Besides the subsidiary plant in Schalkau located in Thüringia, KASTO also operates subsidiaries in England, France, Singapore, China, Switzerland, and the USA, and has sales and service partners in many other countries.

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Five essential functions must be meticulously addressed in fixture design to unlock the full potential of laser-based welding in these industries: ease of loading/unloading, ensuring intimate contact between parts being welded, maintaining consistent component tolerances and fixture registration, and providing a clear line of sight for laser welding and alignment verification through cameras. Neglecting these functions can lead to subpar weld quality, early failures, and significant production setbacks. Figure 1 shows how gaps can impede proper and satisfactory welds.

Streamlined Loading/Unloading

Efficiency is paramount in the fast-paced world of manufacturing. A well-designed fixture must facilitate the smooth loading and unloading of components to be welded. This is especially crucial in industries like medical devices, automotive, aerospace, and EVs, where precision and speed are imperative. A fixture that hampers the easy placement and removal of parts can impede production throughput. This is further highlighted in cases where fixtures act as pallets, preloading components within the fixture before transferring them to the laser system, as shown in Figure 2.

Consider a medical device manufacturing scenario where tiny, intricate components must be laser-welded. An inadequately designed fixture can make it difficult for operators to position these delicate parts accurately. In many cases, fixture selection might involve robotic handling to bring the components together one assembly at a time. In another case, this prolongs the assembly process and increases the risk of damaging the components. In contrast, a fixture that enables quick and precise loading/unloading (manually or automatically) ensures that the welding process remains efficient, minimizes operator errors, and maximizes productivity.

Ensuring Optimal Part Contact

Achieving high-quality welds demands optimal contact between the parts to be joined. Gaps or misalignment between components can result in subpar weld quality, compromising the structural integrity and reliability of the final product. This requirement is particularly vital in aerospace and EVs, where safety and performance are paramount.

Imagine an aerospace component with a slight gap between two critical parts due to inadequate fixture design; Figure 1 shows such a case. These gaps can lead to stress concentrations when exposed to rigorous flight conditions, causing premature component failure. In the EV sector, where battery packs are assembled using laser welding, any gaps or misalignment in the components can affect the overall performance and longevity of the battery, potentially leading to costly recalls. These gaps also lead to a failure mode where the weld acts as a hinge flexure, subjecting it to stress and ultimately causing weld failure over time. Furthermore, such gaps can serve as collectors of oxides and contaminants, leading to further oxidation of the weld from its backside.

Consistent Registration and Tolerances

Maintaining consistent registration and tight tolerances between components is another crucial function of a well-designed fixture. In precision-critical industries such as medical devices and automotive, even minor variations in alignment can result in unacceptable product deviations and increased reject rates. Fixtures must ensure that parts are securely held in their intended positions throughout welding. Tolerance plays a vital role in both the fixture and the components.

Unacceptable component tolerance stack-ups can lead to mispositioned components, part gaps, over- or under-clamping of the element within the fixture, and overall yield issues in the laser welding process. It should be noted that various clamps may be needed, and the setup of these clamps becomes critical; you don’t want heavy clamping, just a slight preload to keep the parts in a fixed position and the overall fixture in place. Figure 3 shows the typical clamping of a palletized fixture.

Unobstructed Line of Sight and Camera Alignment Verification

In laser-based welding applications, maintaining an unobstructed path for the laser beam is evident and crucial for achieving precision. With a variety of off-the-shelf welding optical heads, manufacturing engineers need to be aware of the characteristics of the laser beam output of the lens within that focusing head. The collimated beam diameter received at the focus lens, the cone angle output, the working distance of the focusing lens, and the spot size on the target all play a vital role in the laser material interaction during welding.

Once the welding parameters are established, initial testing parameters can be brought to the laser machine tool. The design of the fixture must take into consideration several factors for proper laser welding, including nozzle gas pressure, nozzle end size, the reflectivity of the material being processed, the angle at which the laser focus head is angled to eliminate back reflections, and the observed visual alignment verification to ensure the accuracy of the welding process.

Fixtures must provide clear access for the laser beam to reach the welding zone and enable operators to verify component alignment through cameras or other machine vision optical systems. These openings must also ensure that the welding spatter can eject and that those openings can be cleaned easily. Figure 4 shows an image of a typical window and how it might get contaminated over time, requiring maintenance and cleaning.

In the automotive industry, for example, welding intricate components within the confined spaces of a vehicle chassis requires fixtures that allow the laser beam to reach every weld joint without obstruction. Additionally, using cameras or vision systems is essential to verify the alignment of components and ensure that the welding process is on track. Narrow weld zones or obstructions caused by weld angles and positioning could result in partial laser beam blockage, leading to poor welding performance and potentially no weld due to such shadowing.

Consequences of Neglected Laser Welding Fixture Design

Neglecting any of these crucial functions in fixture design can have significant consequences. Mismatched part tolerances, gaps between parts due to poor clamping, loose component registration, inadequate vision illumination, or laser beam obstruction can all lead to subpar welding quality and product failures. These failures not only necessitate costly rework and potential recalls, but they also have safety and financial implications for the manufacturer.

Conclusion

Fixture design is integral in laser-based welding applications across industries such as medical devices, automotive, aerospace, and EVs. To achieve the stability and repeatability required for precision welding, fixtures must excel in essential functions: ease of loading/unloading, ensuring optimal part contact, maintaining consistent fixture registration and component tolerances, and providing an unobstructed path for laser welding and alignment verification. Neglecting these functions can lead to subpar weld quality and costly production setbacks.

As these industries continue to push the boundaries of innovation, the role of fixture design in laser-based welding will remain indispensable. Manufacturers must recognize the importance of well-designed fixtures and invest in their development to ensure the success, quality, and reliability of their products in an increasingly competitive marketplace.

By Todd E. Lizotte, Orest Ohar, and Joseph Dagher of Bold Laser Automation, Inc. Bedford, NH

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