The Future for Welding AHSS Tailored Blanks

Presentation SOUTRAC ®
Non-Linear Non Linear Weld System
SOUTRAC - The Future for Welding
AHSS Tailored Blanks
Soudronic Automotive
Soudronic w w w . a u t o s Automotive
t e e l . o r g

Linear
Linear shifted
Non linear
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SOUTRAC ®
Characteristic of Parts

Volume in Mio. TB
70
60
50
40
30
20
10
0
Rails 2002
Rails 2005
Application oriented
Pillars 2002
Pillars 2005
Tunnel/Wheelh.
Tunnel/Wheelh.
Others 2002
Others 2005
Closures 2002
Closures 2005
Body Side /
Body Side /
non linear
linear
250
200
150
100
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SOUTRAC ®
Market Share Non-linear Non linear Tailored Blank
50
0
Market volume total
2000 2005

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SOUTRAC ®
The Solution

max. speed: 120 m/min
max. acceleration: 4 m/s 2
x-axis
max. blank size: 2200 x 3600 mm
max. # of blanks: 4
max. # of welds: 12
max. speed: 30 m/min
max. acceleration: 4 m/s 2
y-axis
weld speed: 2...18 m/min
min. radius: 100 mm
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SOUTRAC ®
The Solution

Function groups
SOUTRAC ®
Edge tracking Gap bridging Weld process Quality control
SOUVIS ® 1
Edge position
measurement
SOUVIS ® 1
(SOUVIS ® 5000)
• Edge position
measurement
• Gap determination
SOUKA ®
Mechanical gap
closing
Laser head
• Monobloc
• Process gas
• Laser position
control
Laser head
• Monobloc
• Process gas
• Laser position control
• Gap driven filler wire
• Double spot
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SOUVIS ® 2
Seam profile top
Seam profile root
SOUVIS ® 3
Seam
homogeneity
SOUVIS ® 2
(SOUVIS ® 5000)
• Seam profile
top
• Seam
homogeneity
SOUTRAC ® combines all functions in only 3 groups
SOUTRAC ®
The Solution

V = 12 m/min
y-axis, weld head
R = 100 mm
x-axis, weld shuttle
SOUTRAC ®
The Solution - Absolute Accuracy of Main Axes
0.1 mm
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Nominal weight
of weld shuttle 4000 kg
Nominal weight
of weld head 300 kg
Nominal position
Measured position
Maximum absolute
deviation 0.05 mm

Main axis x
Main axis y
SOUVIS ® 2 SOUVIS ® 1
Laser head
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
SOUTRAC ®
The Solution - Following a non-linear non linear weld line...
Swivel axis
SOUVIS ® 2
Rotation axis
SOUVIS ® 2
Weld line
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Rotation axis
laser head
Swivel axis
SOUVIS ® 1
Rotation axis
SOUVIS ® 1

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
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SOUTRAC ®
Following a non-linear non linear weld line... (cont.)
SOUVIS ® 1
Laser head
SOUVIS ® 2

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 positiondriven
correction of the
laser head normal to the
actual weld line
Actual edge position
Pre-programmed
edge position
CNC: Ring
buffer for
correction
numbers and
position-driven
laser axis
correction
Deviation calculation
at actual position
Image size SOUVIS ®
1+2: 10 x10 mm
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SOUTRAC ®
Following a non-linear non linear weld line... (cont.)
Laser head with
correction axis
normal to weld line
SOUVIS ® 1
edge tracking

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
CNC: Ring buffer for
gap width and control
of position-driven filler
wire speed
Wire
feeder
Gap width at actual
position
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SOUTRAC ®
Varying Gaps....
Laser head with
filler wire capability
SOUVIS ® 1
gap determination

(Patent pending)
Swivel axis
SOUVIS 2
Swivel axis
SOUVIS 1
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SOUTRAC ®
Mechanical solution for the weld head
Rotation axis
laser head
Laser light cable
Gap driven filler wire

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SOUTRAC ®
Welding Demonstration

SOUTRAC ®
Gap Issue in Non-Linear Non Linear 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 process process
is
mandatory.
Only then a safe and reliable high production output can be guaranteed!
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Gap = Missing material
Possible causes of gap:
Released tension during blanking
Tolerance of part measurement and/or positioning
Large die gap
Damage during transportation/handling
…………………
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SOUTRAC ®
What is a Gap?

Mild Steel
Shear to break ratio
and material deficit
Same shear gap
AHSS
Blanking is a Forming Process:
Good formability of mild steel means good blanking ability
Limited formability of AHSS means bad blanking ability
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SOUTRAC ®
Steel Formability Effects on Edge Quality

Filler wire speed (m/min.) Gap width (mm)
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SOUTRAC ® Solution
Automatic Adjustment of Filler Wire Speed

Position (mm) Gap width (mm)
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SOUTRAC ® Solution
Automatic Adjustment of Laser Position

Gap 0.38 mm
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SOUTRAC ® Solution
The End Result
Corresponding weld with
controlled filler wire

A / TRIP 600
Hardness HV1
0 500
500
450
400
350
300
250
200
150
100
50
0
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]
G / DOCOL DP 1400 1400
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SOUTRAC ® Solution
Examples of Hardness Profiles
Hardness HV1
0 Härte HV1
600
600
500
400
300
200
100
0 1 2
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Distance from seam centre [mm]

SOUVIS® 2
Profile analysis
Seam homogeneity analysis
SOUTRAC ®
Integration of SOUVIS ® 5000 Inline Quality System
Laser head
Integrated position control axis
Gap driven filler wire
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SOUVIS ® 1
Edge position determination
Gap width determination

CMOS Camera with adaptive
response characteristics
Diode
laser line
(Patent pending)
Short pulse
flash light
10 mm
Combined acquisition of
gray scale image and
laser triangulation line
Resolution 0.01 mm
Max. speed 30 m/min
Max. data flow 60 MB/s
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SOUVIS ® 5000
Sensor Principle
10 mm

Easy to operate,
Low number of
parameters
Extraction of seam
geometry information
Reduced maintenance and
spare parts requirements
Easy to integrate
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SOUVIS ® 5000
One Sensor for all Requirements
No complicated and diffuse
fuzzy logic necessary to
combine multiple sensor
arrangements
Extraction of seam
homogeneity information
Microscopic resolution and outstanding
discrimination capabilities (human eye
is the standard)

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SOUVIS ® 5000
SOUVIS ® 1 Edge Tracking
Determination of
• Edge position (laser position
control)
• Gap width (wire feeding control)
• Blank gauge difference
• Blank alignment
• Edge quality

Determination of
• Seam concavity
• Seam convexity
• Mismatch
• Seam width
• Seam roundness
• Lack of penetration
• Porosity
• Expulsion
• Pinholes
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SOUVIS ® 5000
SOUVIS ® 2 Quality Control

Upper seam
surface of a
tailored blank
Texture analysis
Profile analysis
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Pore analysis
SOUVIS ® 2
Image Analysis

Reasons for Failure
Local edge defects
Plasma absorption
Expulsions, holes
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SOUVIS ® 2
Gray Scale Image Analysis
Missing texture

Reason for failure
Partial evaporation of dirt or zinc
particles located between the weld
edges
Porosity
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SOUVIS ® 2
Gray Scale Image Analysis
0.1 mm x 0.3 mm

A safe online quality control is a must for an efficient
production of non-linear tailored blanks.
Its not sufficient to detect some of the relevant weld
failures and some not.
SOUVIS ® 5000 represents the only integrated solution
today capable of detecting all relevant failures in nonlinear
tailored blanks.
SOUVIS ® 5000 performs with only one unique sensor, i.e.
less complexity and more reliability.
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SOUVIS ® 5000
Summary

5
Golf Door (non linear)
Cycle Time: 10.5sec / TB
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SOUTRAC ®
Example Part

6
GMT 370 Body Side
Cycle Time: 36sec / TB
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SOUTRAC ®
Example Part

7
A-MPV (PQ35)
Cycle Time: 25sec / TB
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SOUTRAC ®
Example Part

8
Honda New Accord Front Door Upper
1288
Cycle Time: 16.0 sec / TB
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1346
SOUTRAC ®
Example Part

9
ROVER 75 Front Door)
Cycle Time: 12.5sec / TB
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SOUTRAC ®
Example Part

Produktionstechnik Marke Volkswagen
Tailored Blanks Platinen
A-MPV Seitenteil Innen 4teilige Platine
2000mm
Walzrichtung
ZStE260 Z 100 MB 1,2mm
Walzrichtung
2600mm
ZStE220 Z 100 MB 1,0mm
alternativ: ZStE220i Z 100 MB 1,0mm
Walzrichtung
Walzrichtung
ZStE220 Z100 MB 1,5mm
alternativ: ZStE220i Z 100 MB 1,5mm
550mm
ZStE260 Z 100 MB 1,0mm
Schulz-Marner Stand: 11.00 (K:\...\A_MPV_SLW\Bilder\St_innen_Neues_Konzept\A_MPV_ST_i_2_tei_2l)
PP-F1
Cycle time per side ring 25 sec.
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SOUTRAC ®
Production System for Body Side

Cycle time
15.8 sec
16.3 sec
17.0 sec
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SOUTRAC ®
Production System for Body Side

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SOUTRAC ®
Production System for Body Side

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SOUTRAC ®
SOUTRAC
Layout

Soudronic SOUTRAC ®
The right solution to meet the high
market demand !
regarding
- high output of quality Tailored Blanks
- low scrap rate
- high uptime
based on
- 20 years of experience
- 38 Mash Seam TB welding lines
- 54 Laser Seam TB welding lines (11
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(11- 02)
SOUTRAC ®
Summary