Large‑Format Laser Splicing Welding System

Product Overview

The large‑format laser splicing welding system is an integrated automatic welding equipment combining optics, machinery, electrics, refrigeration and material processing technologies. Adopting fiber‑laser heat source, gantry motion mechanism and dedicated splicing clamping fixture, it performs butt‑splicing welding for multiple metal plates and realizes full‑penetration one‑side welding with double‑side forming.

It is applicable to carbon steel, stainless steel and aluminum alloy plates. The applicable thickness for carbon steel and stainless steel ranges from 0.8‑3 mm, while aluminum alloy shall be no more than 2 mm. The maximum plate size can be customized. The splicing gap shall not exceed 10 % of plate thickness. Post‑weld plate deformation is less than 3 ‰ with smooth and uniform welds free of missing weld and other defects. Reserved expansion interfaces allow connection with industrial robots for automatic loading and unloading. Designed for automated splicing production of sheet‑metal pre‑fabricated parts, it replaces traditional arc‑welding processes to improve weld quality and reduce post‑weld correction and polishing workload.

System Composition

The whole system adopts modular design and consists of seven major parts: laser generation unit, cooling unit, welding execution unit, clamping fixture unit, visual monitoring unit, motion‑control unit and auxiliary process unit.

1. Fiber Laser Generation Unit: 3000 W fiber laser with modular fully‑enclosed optical modules and excellent beam quality, providing high‑energy‑density heat source for splicing welding.
2. Cooling System Unit: Industrial water chiller with dual‑temperature control at ±1 ℃ precision. It cools both laser source and optical lenses to prevent lens condensation damage. It supports fault diagnosis, RS485 communication and multiple safety protections.
3. Laser Welding Head Unit: ND24 high‑power welding head with drawer‑style modular lens structure. It supports multi‑mode oscillation welding (figure‑8, rectangle, etc.) to reduce spatter. Multi‑zone temperature monitoring with alarm shutdown and coaxial CCD observation are integrated.
4. Gantry Motion & Clamping Fixture Unit: X/Y/Z three‑axis gantry motion module delivers high‑precision travel for welding torch. Dedicated alignment‑and‑clamping mechanism positions and fastens workpieces to control misalignment and splicing gaps and restrain thermal warping.
5. Visual Monitoring Unit: High‑definition CCD monitoring system with 800 TV‑line resolution. Coaxial real‑time molten‑pool observation assists operators in weld‑forming monitoring and process debugging.
6. Control System Unit: C6L four‑axis laser welding control system including control card and host‑computer software. It supports DXF import, teach‑in programming, process‑parameter storage, machining simulation and alarm handling, with Chinese‑language HMI. Wire‑feeder is optional for filler‑wire welding.
7. Auxiliary Supporting Unit: Three‑phase voltage stabilizer ensures stable operation under fluctuating input voltage. Follow‑up fume‑extraction device moves synchronously with welding torch to collect welding fume and sparks. It also includes control cabinet, host computer, monitor and keyboard‑mouse set.

Technical Features & Technical Challenges

Core Technical Features

1. Superior Weld Formation: Achieves full‑penetration one‑side welding with double‑side forming. Welds are smooth and even. Post‑weld plate deformation ≤3 ‰, which greatly cuts correction and polishing procedures and guarantees high production yield.
2. Flexible Process Performance: The welding head supports multiple oscillation modes with adjustable oscillation width, speed and segmented power to suppress spatter. Non‑wire welding is available; optional wire‑feeder enables filler‑wire welding for carbon steel, stainless steel and aluminum alloy sheets.
3. Reliable Optical Design: Drawer‑type quick‑change lens structure simplifies maintenance. Dual‑temperature water cooling avoids lens condensation. Multi‑zone real‑time temperature monitoring triggers auto‑alarm and shutdown to protect key optical components.
4. Visualized Debugging & Operation: Coaxial CCD monitors molten pool in real time. Chinese‑language host‑computer software supports graphic import, teach‑in and process‑library storage for low‑operation barriers. RS485 communication supports centralized monitoring.
5. Good Expandability: Reserved hardware interfaces connect with industrial robots for automatic loading/unloading to build full‑automatic production lines. Standardized consumable spare‑parts enable convenient replacement.

Core Technical Challenges

1. High Sensitivity to Splicing Gap: The splicing gap shall not exceed 10 % of plate thickness. Excessive gap easily causes incomplete penetration or weld collapse, which imposes high requirements on upstream blanking precision and clamping‑fixture accuracy.
2. Difficulties in Aluminum‑alloy Welding: Aluminum alloy is limited to max. 2 mm thickness. As a high‑reflectivity material, it may generate back‑reflected laser light that damages the laser source, requiring matched process parameters and shielding‑gas configuration.
3. Thermal‑deformation‑induced Seam Offset: Thermal warping occurs during long‑distance splicing welding, shifting seam position. Reliable fixture clamping and visual‑aided manual or closed‑loop correction are required.
4. Protection of Optical Components: Welding spatter and fume contaminate protective lenses. Condensation or dirt leads to power attenuation. Combined measures including water‑cooling temperature control, fume extraction and regular maintenance are mandatory.

Typical Applications

This laser splicing welding system is developed for thin‑gauge metal‑plate splicing. Typical scenarios include sheet‑metal cabinet plate splicing, large stainless‑steel panel joining for kitchen‑bath products, decorative metal‑plate welding, new‑energy sheet‑metal components, electrical‑equipment enclosure splicing, pre‑fabricated aluminum‑alloy sheet welding, and splicing processes after decoiling and blanking. Target customers cover sheet‑metal fabricators, stainless‑steel product manufacturers, new‑energy component suppliers and general‑equipment manufacturers.