PROCESS TECHNOLOGY. for lightweight design in automotive industry. TRUMPF Laser- und Systemtechnik GmbH. Marc Kirchhoff Industry Management Automotive

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1 TRUMPF Laser- und Systemtechnik GmbH PROCESS TECHNOLOGY for lightweight design in automotive industry Marc Kirchhoff Industry Management Automotive Ditzingen,

2 Design fit-for-laser Lightweight design using sheet metal flangeless design Concept conventional Reduction of weight, flangeless design and integrated functions tailored parts possible, using different materials and thicknesses simplified clamping devices derivates easy to realize flangeless design using laser technology Resistant Spot Welding Laser-Welding Number Dots: 16 Process-Time 60s Weight 1,4 kg Seam Length: Process-Time Weight 700 mm 6 s 0,96 kg 2

3 Project StreetScooter StreetScooter GmbH, Aachen German postal service is using the StreetScooter Spin-Off of the RWTH actual small production rate actual design fit for using resistant spot and arc welding Underbody is the first part, which is design flangeless Underbody is the first part, which is design flangeless 3

4 Concept of the StreetScooter Car body Streetscooter floor assembly as central element of complete body structure especially for crash performance saving space and weight means more payload and / or more batteries floor assembly flangeless design, based on plug-in connections reduces number of clambing devices significantly new design should save weight and space and increase productivity 4

5 Detail of the floor assembly side members seperator bottom-plate cross-member

6 Basic design principle detailed analysis of the part function replacement of flanges with plug-in connections cutting of all flanges, except flanges needed for assembling to other parts complete new design of parts, based on the described design principle

7 Developing of Laser welding process tests on sheet metals for welding new geometry tests on all relevant material thicknesses, needed in the floor assembly use of Remote-Technology for welding, especially because of needed seam geometry use of a PFO and a TruDisk Laser for welding test Remote-Laser-Welding used for processing

8 Production of the RWTH (PEM) cutting bending assembling &welding 8

9 Projekt StreetScooter New Underbody very simple clamping devices, most of the parts are fit together without clamping devices completely new design for the underbody 9

10 Benefits of new design "old" design 55 "new" design bends saw cuts holes significant reduction of production steps less handling and logistic steps reduce production-time significant reduction of weight, using the same material like before (steel) % Weight less production steps and weight 20 0 "old" design "new" design 10

11 Design fit-for-laser New Design needs new welding technology next generation of remote systems remote welding of fillet welds need sensor systems for positioning the laser beam especially for handling tolerances use of intelligent optical systems for high productivity and quality needed Remote-Systems need to be intelligent for this new kind of applications 11

12 welding speed m/min Schweißgeschwindigkeit in m/min Laser-Joining The benefits of laser joining are used for several years P = 8 kw P = 6 kw P = 4 kw P = 2 kw Material: Baustahl Optik: CFO50 Fokusdurchmesser: 0,28 mm TLS259oy laserwelding EB UP HF UP EB MIG MIG EB MIG MIG MAG MAG Rollnaht MAG MAG 5 WIG WIG Punkt WIG WIG Einschweißtiefe in mm welding depth Pros Laserwelding: fast low heat affected zone low energy input contact free flexible conventional laser welding optic remote welding optic 12

13 mm New ScanLine System 1. online seam tracking 2. coaxial observation of process-zone, using a CMOS-camera 3. integrated lightning systems for increasing visibility of seam. Use of light-sectioning measurement 4. use of proven methods and algorithms out of the SeamLine-System 5. control of path compensation of mirrors, using a closed loop control projected laser line integrated camera LED light 13

14 Laserwelding using ScanLine 14

15 New Design needs new production systems production systems based on tooling machines increasing numbers of derivates of car models especially new car types like PHEV, EV, HEV, etc.) decreasing numbers of lot sizes needs more flexibility in production future car concepts consist of more mixed material (Aluminum, Steel, CFRP, ) the effort for laser safety have to be reduced new production system for future car concepts 15

16 New production system based on standard tooling machines prototype factory in Aachen Bending assembling & welding of ZSB using a Robot Cell assembling of Car Cutting 2D-Laser-Machine 16

17 Laser Processing of CFRP 17

18 Lightweight Design made by laser what can we do today flangeless design based on laser technology integration of functions joining of plastics joining of metal and plastic laser processing of fiberreinforced plastics joining of aluminum and steel 18

19 The StreetScooter is on the road 19

20 Welding Hotforming Lightweight Design Drives Drives CARS MADE BY LASER Assembly 20

21 TRUMPF Laser- und Systemtechnik GmbH YOUR CONTACT Marc Kirchhoff Industry Management Automotive PROCESS TECHNOLOGY, Marc Kirchhoff

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