CHALLENGES OF AN ECONOMIC REMOTE LASER WELDING

Adam Opel AG @ EALA 2017 PROCESS

Udo Eller, Manager ME Body Closures & BIW

Manufacturing Engineering Body
Systems
www.opel.com
www.opel.com
AGENDA

 Opel Astra doors with Remote Laser Welding

 Remote Laser Welding vs. Spot Weld

 Launch phases

 Lessons Learned & Outlook

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EALA 2017 / Opel / Vauxhall ME BS / U.Eller
OPEL ASTRA FRONT DOOR

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EALA 2017 / Opel / Vauxhall ME BS / U.Eller
DOORS OPEL ASTRA

• Opel Astra platform is globally produced in 8 assembly plants

on 4 continents
 Common design of door inner assembly for all regions

• Opel Astra doors initially engineered for spot welding

 Front doors: 10 single parts
76 weld spots
 Rear doors: 9 single parts
65 weld spots

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EALA 2017 / Opel / Vauxhall ME BS / U.Eller
PROJECT LAUNCH PHASES

Phase 1 Phase 2 Phase 3

Phase 1 / December 2013

Enthusiastic & encouraged to
engineer

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EALA 2017 / Opel / Vauxhall ME BS / U.Eller
CONCEPT COMPARISON RLW VS.
RSW
Spot Welding Laser Welding
(RSW) (RLW) Quick Tool
Change is
the big
enabler with
RLW !

Furthermore:
- less Robots
- less Energy
- less Grippers
- less tool
changer
30 % Less
Floor Space
required

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EALA 2017 / Opel / Vauxhall ME BS / U.Eller
REMOTE LASER WELDING VS.
SPOT WELD
Spot Weld Laser
Time / Weld ~3s ~ 0,5 s

Robots ASM 64 32
Inner *)
Stations ASM 5 2
Inner
Floor Space *) ~ 4800 m² ~ 3400 m²

Operators/3 shifts 54 36
*)
Flexibility (incl. o +
SW) shown for 8 installed cells in 2
* Figures
plants
Invest *) Approx. same invest for both concepts

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EALA 2017 / Opel / Vauxhall ME BS / U.Eller
REMOTE LASER WELDING DOORS

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EALA 2017 / Opel / Vauxhall ME BS / U.Eller
REMOTE LASER WELDING DOORS

• Total Laser welds: 6096 mm (1 Weld Spot ≙ 24 mm Laser

weld )
• Welding Speed: up to 10,5 m/min OTF
• Material Thicknesses: 0,65 mm – 2,2 mm
• Material Coatings: HDG, AlSi (PHS), ZM

Equipment
• Laser (Welding): Trumpf Disc Laser 6001
• Laser (Dimpling): Trumpf Disc Laser 3001
• Remote System: Blackbird + Scanlab Intelliweld

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EALA 2017 / Opel / Vauxhall ME BS / U.Eller
RLW VS. SPOT WELDING
Advantages
• Fast welding process (factor 6-
10)

• Higher stability of dimensions

• Joining without applying Force

Identified risks
• Challenges:
•3-layer welds challenging
•Visibles welds

• Shiming requires subsequent

re-programing of the robot

• Higher maintenance effort

(cleaning, protection glasses)

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REQUIRED PART FITTING FOR RLW

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EALA 2017 / Opel / Vauxhall ME BS / U.Eller
BACKUP CONCEPT

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EALA 2017 / Opel / Vauxhall ME BS / U.Eller
PROCESS CONTROL PLAN FOR RLW

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EALA 2017 / Opel / Vauxhall ME BS / U.Eller
PROJECT LAUNCH PHASES

Phase 1 Phase 2 Phase 3

Phase 2 / December 2014

Challenges

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EALA 2017 / Opel / Vauxhall ME BS / U.Eller
WELD QUALITY DURING PPV
Renf. rear side door upper
hinge

Renf. rear side door lower

hinge

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EALA 2017 / Opel / Vauxhall ME BS / U.Eller
RLW WITH OXIDE LAYER

Cut position B
Oxide 2-4 micro
meter

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EALA 2017 / Opel / Vauxhall ME BS / U.Eller
RLW OF CLOSURES – OUR
CHALLENGES
Visible laser weld seamsLessons Learned:
No laser weld seams in so called „wet
area“

OK

NO
K

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EALA 2017 / Opel / Vauxhall ME BS / U.Eller
RLW OF CLOSURES – OUR
CHALLENGES
• Initial target was 4000 doors per one
lens

• However random weld splatters are

limiting average lens life

• Current situation:
• 900-1200 doors per lens only
achieved on LH Rear Door

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EALA 2017 / Opel / Vauxhall ME BS / U.Eller
HIGH DIMENSIONAL STABILITY
WITH RLW

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VIDEO FROM REGULAR PRODUCTION

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EALA 2017 / Opel / Vauxhall ME BS / U.Eller
PROJECT LAUNCH PHASES

Phase 1 Phase 2 Phase 3

Phase 3 / December 2015

Continuous improvement

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EALA 2017 / Opel / Vauxhall ME BS / U.Eller
CHALLENGES REMOTE LASER
WELDING

Cover Glass Lifetime

Non-Saleable Saleable SORP Today

Welds / Cover Glass

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EALA 2017 / Opel / Vauxhall ME BS / U.Eller
RLW AFTER PROCESS OPTIMISATION

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EALA 2017 / Opel / Vauxhall ME BS / U.Eller
LESSONS LEARNED AND OUTLOOK
Today
• Still a lot of continuous improvement work to be done to
make RLW efficient as RSW

• Design engineers need better understanding of RLW process

in order to design more robust equipment (e.g. impact of
process air, part position )

• Fatique strength capability of RLW seams more critical

compared to RSW. Remedy: seam smoothing

Future
• RLW without „Dimpling“ will increase the number of more
efficient applications

• Flexible welding cell for both steel / aluminum are required

faster then expected.

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EALA 2017 / Opel / Vauxhall ME BS / U.Eller
Udo Eller, Manager ME Body Closures & BIW

THANK YOU.

www.opel.com