T E C H N O L O G Y F O R T H E W E L D E R ’ S W O R L D . LASER SYSTEMS – holistic solutions from laser joining to process monitoring and quality assurance www.binzel-abicor.com Content | Our solutions for manufacturing Tactile laser welding Remote laser welding 01 04 02 03 06 07 Product Page 01 MPH Tactile 4–5 02 MFS-V3.1 6–7 03 WELDEYE System 8–9 04 intelliWELD II PR/FT 3D packages 05 intelliSCAN FT with ScaVis 2 05 10 – 11 12 – 13 Seam tracking Process monitoring and quality assurance 09 08 Product Page 06 Tornadoblade® 14 – 15 07 4D.watcher 16 – 17 08 3D weld inspection 18 – 19 09 iSENSE TRACK 20 – 21 3 Next generation tactile laser joining head 4 MPH Tactile Sophisticated yet simple to use laser welding technology made by experts for experts. For wire-based laser applications where reliability and highest quality counts, the MPH Tactile is a first class offering. Proudly developed together with our partner Photonic Tools. ■ Simplified optical design for high laser power use with focus stability ■ Smart modular design for maximum flexibility ■ Best results when combined with the Master-Feeder-System MFS-V3.1 from ABICOR BINZEL ■ Communication via control modules that “speak the user’s language” ■ Sophisticated sensor technology with unique maintenance and repair concept User-friendly zoom collimation ■ Imaging scales from 2.7 to 5.0 can be achieved with just one optical system ■ Only one optical system for a wide range of tasks Sophisticated sensor concept ■ Each individual optical element in the beam path can be monitored in real time ■ In the event of contamination or damage, a warning message is sent to the machine control system Efficient maintenance and repair concept ■ Rail-guided interchangeable cassettes allow quick and reproducible exchange of contaminated optical elements ■ A simple exchange of lens modules enables conversion from brazing configurations with zoom collimation to welding configurations with small magnification (down to M = 1.0) 5 The future of wirefeeding in laser welding and brazing 6 MFS-V3.1 A living concept – for technological advancement! In co-operation with leading car manufacturers and ABICOR BINZEL ROBOTIC SYSTEMS, the specific requirements of laser and arc processes in vehicle construction were analyzed. The result is a fully digitally controlled, high-precision wire-feeding system that is optimally geared to the high demands of the respective production environment in every respect: MFS-V3.1 – the third-generation master feeder system with completely redeveloped eBOX and service software. The MFS-V3.1 is used in laser-based joining processes using welding filler metal or braze for relatively small process windows. It is ideally suited for applications requiring high connection strength and finish quality and which allow little or no reworking. The system feeds even critical welding filler metals reliably and without problems. It therefore also allows the integration of special wire electrodes into automated series production and ensures technologic advancement in the long term. MFS-V3.1 in brief Precise & dynamic ■ Independently and digitally controlled motors, make synchronization superfluous ■ Fast motor control due to 32-bit processor ■ High accuracy even at very low wire feeding speeds Reliable processing & easy to install ■ Proportional speed control ■ Control system: analog, digital or by fieldbus ■ Automatic master pull or push-push recognition (with MF3-Laser and MF3-Laser-Rear) ■ Wide-range input ■ Compatible with MFS-V2 User-friendly & low-maintenance ■ Licence-free service software for visualization, documentation, diagnostics and maintenance ■ Job mode selectable (64 jobs) ■ Programming of maintenance intervals ■ With safety shutdown and inching function optionally available 7 This camera won’t miss a weld defect 8 WELDEYE system The WELDEYE camera-based process monitoring system from Lessmüller offers optimal process visualization and evaluation when tactile laser welding. Enables easy, fast detection of flaws in welded or brazed tailgates, car doors and battery boxes. ■ ■ ■ ■ ■ ■ ■ ■ Perfectly matched variant for MPH Tactile laser processing optics Ensures a consistently high level of quality for laser welding of complex parts Detects interruptions in the seam surface as well as lateral connection defects Realizes process monitoring for every single weld Creates live images with a sampling rate of up to 500 Hz Accelerates process optimization through visualization High safety when welding complex components Worldwide application and service support ■ Online process monitoring ■ Data management and documentation ■ The benchmark in process monitoring The following seam irregularities are detected: ■ Interruption in the weld seam or brazed seam ■ Surface defects ■ Lateral connection defects 9 Powerful remote laser technology for short cycle times in automotive production 10 intelliWELD II PR/FT 3D packages A holistic solution offering sophisticated remote laser welding technology where there is demand for shorter cycle times in vehicle component production. This innovative technology package including the intelliWELD II PR guarantees optimum results in the remote laser welding of brackets, hang on parts, seats and battery boxes. ■ Ideal yet easy to install technology when it comes to the laser welding of challenging vehicle parts ■ High quality welds with comparatively short cycle times ■ Package includes highly dynamic 3D scanner system as well as intelligent and efficient software ■ Economical on-the-fly synchronization; On-the-fly (OTF) welding allows scanner to synchronize with robot motion to reduce processing time to the shortest possible and increase system efficiency ■ intelliWELD II PR available in single mode configuration for optimum performance in battery and thin foil welding ■ intelliWELD II also offered in FT (F Theta) configuration ideal for on-the-fly welding of lap joints ■ Powerful OCT technology using the xHAWK scanner package for inspection and seam tracking applications ■ Worldwide application and service support OCT technology – seam tracking, quality control, and more … In optical coherence tomography (OCT), the component surface is scanned at high frequency by an optical measuring beam. By comparing it with a reference beam of defined length, distance is measured locally and precisely and a height profile is created, which enables the reliable detection of joints and component edges. In addition, OCT can be used to detect surface irregularities thus identifying areas of repair and enable further detail to support corrective actions to enhance overall process quality. The latter allows conclusions about the seam depth already during the process. The combination of an impact position detection with downstream inline inspection of the seam topology makes OCT a powerful tool for automated production, for example in door manufacturing. 11 Flexible remote laser welding for e-mobility 12 intelliSCAN FT with ScaVis The 2D remote laser welding optics intelliSCAN FT with ScaVis camera from Blackbird combines sophisticated control technology, a highly dynamic scanner system, optimally adjusted optics and outstanding user-friendliness. Excellent reproducibility for complex joining tasks in the fast-growing e-mobility sector. ■ ■ ■ ■ ■ ■ ■ Fast laser positioning and high-precision processing Freely programmable oscillation with high frequency ScaVis camera for position correction of welds 2D on-the-fly operation available Combination with additional linear modules available Shortens the ramp up to serial production through the use of sophisticated offline programming software Worldwide application and service support Flexible use for copper and aluminum materials The technology package with this complete system, everything simply fits when it comes to laser welding in electromobility. ■ RobotSyncUnit (RSU) – intelligent software ■ ScanControlUnit (SCU) – highly efficient control ■ intelliSCAN FT – powerful 2D scanner ■ ScaVis – highly intelligent image recognition and processing Using ScaVis, characteristic geometries of the component to be welded can be defined in advance and the welding path can be specified and parameterized offline based on the camera images. Before laser welding, the software compares the real component contours with the pattern stored in the memory. If deviations outside defined limits are detected, the system generates a warning to the machine control and prevents the execution of the weld. If there are no deviations, the system always performs the weld in relation to these characteristic features. 13 Air-knife blower technology enabling more efficient remote welding processes 14 Tornadoblade ® The optimal shield for your laser welding optics To ensure reliable and stable performance in laser welding, it is essential to protect the welding optics from spatter and fumes. Even the smallest deposits on the optically coated surfaces inevitably lead to performance losses, process instability, and eventually damage to the protective glass or even the entire optics. This is where the Tornadoblade® comes in: A powerful airflow is generated in a ring chamber located beneath the welding optics and set into rotation. This creates a strong, rotating air vortex that is directed downward, blowing welding fumes and metal particles away at the source. At the same time, welding spatter is deflected far enough that it can no longer reach the sensitive, coated surfaces of the optics. As a result, your welding optics stay clean, and your processes remain stable. ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Tested with laser power up to 8 kW (@ 1070 nm) Reduces compressed air consumption by 98 % Eliminates the need for additional air nozzles for process air in fixtures Extends the life of protective lenses Electrical power requirement of only around 4 kW Pays for itself quickly, virtually maintenance-free Improved part accessibility Directionally independent Enhances weld seam quality with deeper penetration at the same energy input Stabilizes quality monitoring (e.g., with 4D.watcher, WELDEYE, etc.) Tornadoblade® – the flexible solution for your optics! Tornadoblade® is independent from welding optics manufacturers, offering full compatibility and versatile application options. Whether for large or small field scanning or for a broad range of fixed optics, Tornadoblade® fits perfectly and ensures maximum efficiency. 15 The guarantor for process stability in your laser process 16 4D.watcher & 4D.TWO sensor With this online laser process monitoring device from 4D Photonics you can significantly reduce expensive product testing and optimize quality assurance. An economical and process-safe solution to manage increasing complexity in production. ■ Reliable detection of process deviation during laser processes ■ Prevents continuation of defects immediately ■ Records and evaluates data from production processes such as part number, part type, process positions, NOK or OK signals ■ Can be quickly integrated into remote optics from Blackbird and other leading system manufacturers ■ Increases production efficiency ■ Worldwide application and service support 4D.TWO sensor for process monitoring As part of the 4D.watcher sytsem, 4D.TWO is your all-purpose multi sensor data source for laser applications where process monitoring for quality control is crucial. 4D.TWO features and benefits ■ Provides >1M sample/s of 42+ single sensors, in one compact device ■ Combines relevant raw channels from the 42+ channels to classify error types for your laser application ■ One-click teach-in process for easy parameterization ■ Networks with other 4D.TWO data sources ■ Applicable to almost all laser process monitoring applications ■ Compact and capable of multi-parameter monitoring with one sensor only 17 A real game changer in automated end-of-line weld inspection 18 3D weld inspection JOSY The high-speed all-in-one inspection system enables optimum control in almost all welding applications – contactless, fast, reliable. With JOSY you have effective support for quality assurance, complete documentation and traceability for your process, as well as the ability to enhance your operations by improving first-pass quality and increasing your overall production efficiency. Most compact narrowest sensor head on the market Non-destructive automated 3D weld inspection Maximum accessibility for material inspection, inspects EVERY weld completely 50 % faster than other sensors in the market Drastically reduces rework costs due to visualization of weld seam defects Management dashboard for statistical evaluation of most significant process variations ■ Worldwide application and service support ■ ■ ■ ■ ■ ■ 3D scan of weld seam dimensions and weld seam faults: Geometric inspection characteristics ■ ■ ■ ■ ■ ■ ■ ■ Length Width Throat thickness Cross sectional area Toe Position Asymmetry & leg length Concavity, convexity Visible welding faults ■ Pores – Macro Pores – Micro Pores – Porosity (pore nests) ■ Holes ■ Undercuts ■ Incomplete welds ■ Incompletely filled groove ■ Spatter Until now, the above mentioned and similar defects were only detected in random samples by costly and sometimes destructive testing methods. JOSY reveals even the smallest defect and visualizes it clearly without damaging the component – even with highly reflective surfaces. 19 The eye of the robot 20 iSENSE TRACK Our torch guidance systems iSENSE TRACK ARC 15, 30 & 50 transform robotic welding. Deviations in the work piece are easily rectified. The system detects the position of the joint and adjusts the welding path in real time. Reducing your scrap rate and rework costs. ■ A complete series of seam tracking sensors with a horizontal field of view from 15 to 50 mm suitable for a wide variety of applications ■ Minimal error detection as low as 0.1 mm dependent on sensor model ■ Combined in head data capture eliminates the need for an additional processing ■ Easy user-friendly setup when using standard tablets ■ Weld seam information can be recorded and edited offline to optimize the tracking performance ■ Interfaces available for many industrial robots including but not limited to FANUC, YASKAWA, ABB, KUKA and Kawasaki 21 Notes 22 23 T E C H N O L O G Y F O R T H E W E L D E R ’ S W O R L D . MANUAL ■ MIG/MAG welding torches ■ TIG welding torches ■ Plasma cutting torches ■ Plasma welding torches EXTRACTION TECHNOLOGY ■ Fume extraction systems ■ Fume extraction torches ■ Fume extraction & power source combination system ROBOTIC SYSTEMS ■ Robot torches MIG/TIG/Plasma ■ Robot switch-off protections ■ Torch cleaning stations ■ Wire cutting devices ■ Robot power source ■ System solutions for cobots ■ Pipe welding robot ■ Wire feeder systems ■ Seam tracking sensors ■ Gas management systems LASER SYSTEMS ■ Remote laser scanner ■ Tactile laser optics ■ Wire feeder systems ■ Process monitoring tools ■ Weld seam inspection ORBITAL WELDING ■ Orbital welding systems ■ Positioning bands ■ Coated contact tips HARD AUTOMATION ■ Welding tractors ■ Welding tractor & power source combination system ■ MIG/MAG automatic torches ■ Plasma automatic welding and cutting torches WELDING ACCESSORIES ■ Wear parts MIG/TIG/Plasma ■ Intermediate cable ■ Sockets and plugs ■ Electrode holders ■ Gouging torches ■ Gouging electrodes ■ Utilities and tools ■ Cooling units ■ Wire feeding units ■ Equipment for weld seam treatment ■ Anti-spatter agents, sprays and pastes COMPLETE SOLUTIONS FOR INDIVIDUAL APPLICATIONS ABICOR BINZEL USA, Inc. 650 Medimmune Ct., Suite 110 Frederick, MD 21703-8619 T: 301.846.4196 customerservice@abicorusa.com www.binzel-abicor.com PRO.L009.EN-US • Bi-500.09.2024 • Printed in USA • © Copyright • All trademarks named in this brochure are the property of the respective companies. Our product range F O R T H E W E L D E R ’ S W O R L D . Our product range MANUAL ■ MIG/MAG welding torches ■ TIG welding torches ■ Plasma cutting torches ■ Plasma welding torches EXTRACTION TECHNOLOGY ■ Fume extraction systems ■ Fume extraction torches ■ Fume extraction & power source combination system ROBOTIC SYSTEMS ■ Robot torches MIG/TIG/Plasma ■ Robot switch-off protections ■ Torch cleaning stations ■ Wire cutting devices ■ Robot power source ■ System solutions for cobots ■ Pipe welding robot ■ Wire feeder systems ■ Seam tracking sensors ■ Gas management systems LASER SYSTEMS ■ Remote laser scanner ■ Tactile laser optics ■ Wire feeder systems ■ Process monitoring tools ■ Weld seam inspection ORBITAL WELDING ■ Orbital welding systems ■ Positioning bands ■ Coated contact tips HARD AUTOMATION ■ Welding tractors ■ Welding tractor & power source combination system ■ MIG/MAG automatic torches ■ Plasma automatic welding and cutting torches WELDING ACCESSORIES ■ Wear parts MIG/TIG/Plasma ■ Intermediate cable ■ Sockets and plugs ■ Electrode holders ■ Gouging torches ■ Gouging electrodes ■ Utilities and tools ■ Cooling units ■ Wire feeding units ■ Equipment for weld seam treatment ■ Anti-spatter agents, sprays and pastes COMPLETE SOLUTIONS FOR INDIVIDUAL APPLICATIONS Alexander Binzel Schweisstechnik GmbH & Co. KG Kiesacker · 35418 Buseck · GERMANY T +49 (0) 64 08 / 59-0 F +49 (0) 64 08 / 59-191 info@binzel-abicor.com www.binzel-abicor.com PRO.L009.EN • Bi-1.000.10.2024 • Printed in Germany • © Copyright • All trademarks named in this brochure are the property of the respective companies. T E C H N O L O G Y T E C H N O L O G Y F O R T H E W E L D E R ’ S W O R L D . MANUAL ■ MIG/MAG welding torches ■ TIG welding torches ■ Plasma cutting torches ■ Plasma welding torches EXTRACTION TECHNOLOGY ■ Fume extraction systems ■ Fume extraction torches ■ Fume extraction & power source combination system ROBOTIC SYSTEMS ■ Robot torches MIG/TIG/Plasma ■ Robot switch-off protections ■ Torch cleaning stations ■ Wire cutting devices ■ Robot power source ■ System solutions for cobots ■ Pipe welding robot ■ Wire feeder systems ■ Seam tracking sensors ■ Gas management systems LASER SYSTEMS ■ Remote laser scanner ■ Tactile laser optics ■ Wire feeder systems ■ Process monitoring tools ■ Weld seam inspection ORBITAL WELDING ■ Orbital welding systems ■ Positioning bands ■ Coated contact tips HARD AUTOMATION ■ Welding tractors ■ Welding tractor & power source combination system ■ MIG/MAG automatic torches ■ Plasma automatic welding and cutting torches WELDING ACCESSORIES ■ Wear parts MIG/TIG/Plasma ■ Intermediate cable ■ Sockets and plugs ■ Electrode holders ■ Gouging torches ■ Gouging electrodes ■ Utilities and tools ■ Cooling units ■ Wire feeding units ■ Equipment for weld seam treatment ■ Anti-spatter agents, sprays and pastes COMPLETE SOLUTIONS FOR INDIVIDUAL APPLICATIONS Abicor Binzel Technoweld Pvt. Ltd. S. No. 297 · Village Urawade · Taluka Mulshi · Dist. Pune Maharashtra · INDIA (Pin 412 115) T +91 (20) 66 74 39 00 sales@abicorindia.com www.binzel-abicor.com PRO.L009.ENIN • Bi-500.10.2024 • Printed in India • © Copyright • All trademarks named in this brochure are the property of the respective companies. Our product range
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