1、TASC Process - ImplementationOliver MllerschnInternational SalesProject Management PowertrainTRUMPF Laser- und Systemtechnik GmbHTask Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch2ContentsnExamples of implemented projects Powertrain Applications Laser welding of guid
2、e rollers Car differential gears Utility vehicle differential gears Welding of planet carriers Beam sharing =double clutch Compact beam delivering system Visco damper Fly wheel Laser markingnTRUMPF servicesTask Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch3Distributi
3、on Of ForcesMotorDepressant PartsTorque ConvertersClutchesGearboxDriveshaftsDifferentialsBrakes, HubsWheelsTask Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch4Typical Powertrain ApplicationsnRimsnRims / Shaftsn Shafts / Hubsn Chainwheelsn Rimsn Housing and Crowngearn
4、Housing / Housing(casting)n Shafts and ConnectorsWheelsBrakes, HubsDifferentialsDriveshaftsn Synchron Gearsn Bevel Gears / Shaftsn Gears / ShaftsManuel:nClutch Discs / HubsDouble Clutches:n Housings / Hubsn SealsTorque Converters:n Housings / Hubsn Two-Mass-Flywheeln Visco Dampersn Crankshafts/Camsh
5、aftsn Countershaftsn Gear and Shaftsn Adaptive Camshaftsn SensorsGearboxTorque ConvertersClutchesDepressant PartsMotorTask Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch5Rotation-Symmetrically Partsn Dampersn Pressure tanks for brake boostersn Flat-base tappetSuspensi
6、onsPressure tanksValve trainn Airbag ignitionn Steering shaftn Hydraulic StabilizerAirbag technologySteering mechanismStabilization of chassisTask Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch6References in PowertrainSuspensionsBrakes / HubsDifferentialsDriveshaftsGe
7、arboxTorque convertersClutchesDepressant partsMotorTask Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch7Gear weldingsDifferential gearPlanet carrierCarrier partsGear partsShaft drivesLASER SYSTEMSTRUMPF Laser- und Systemtechnik GmbHApplication samples PowertrainTask Pr
8、ocess Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch8Task: Laser welding of guide rollersnShorten the process chain, reduce cycle timenIntegration in complex, overall production processnNo refinishing work after weldingnNo negative impact on shape and position tolerancesnWeld
9、ing with filler material instead of warmingPillow block2 weldsHardened flanks (4x)Task Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch9System design: Laser welding of guide rollersnComponent infeed and outfeed on conveyor beltnFully automated workpiece loader (max. 20
10、kg)nChuck with component sensingnHold-down with integrated component length measurementnTSD for gap measurement and seam trackingnSelective removal of out-of-spec. parts / critical parts and refinishingTask Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch10TLC1000 Power
11、train Guide Rollers“Task Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch11Task: Car differential gearsRear axle gearingFront axle gearingBoltedLaser weldedApplicationComparison BMW AGTask Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch12C
12、ar differential gearsMotivation for using the lasernCost reduction as screwed joints are eliminatednWeight reductionnSmaller part dimensionsnReduced noise emissionChronologynInitial contact November 2003nJoint process development BMW AG TRUMPFnPPAP Feb. 2006TechnologynGGG60 with case-hardened steel
13、nLaser welding with filler materialBoltedLaser weldedTask Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch13System design: Car differential gearsnCirculating conveyor belt with work piece carrier, data media systemnCleaning of the jointsnFully automated work piece loade
14、rnCombined press-in and welding fixture with force stroke monitoring, shuttle principlenTSD for gap measurement and seam trackingnOnline process monitoringnCalorimetric laser power measurement at the work piece offlinenBrush stationnSelected removal of out-of-spec parts / critical partsLaser cleanin
15、g3 operating stationsBrushingPart turningTask Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch14TLC1000 Powertrain Differential Gear“Task Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch15Task Process Implementation: Realized ProjectsPrasen
16、tationen TRUMPF Vorlage deutsch16Task: Truck differential gearsApplicationComparison boltedlaser weldedTask Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch17Task: Utility vehicle differential gearsTasknDiameter: 380 510 mmnWeight: 90 120 kgnEliminates 29 screws (12.9)n
17、Cycle time: 90 secondsChronologynInitial contact: July 2003nLaser-friendly design and process development of component in cooperation between Arvin Meritor and TRUMPFnPPAP May 2006Task Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch18System design: Utility vehicle gear
18、snIntegrated in assembly linenLoading and unloading by an articulated-arm robotnCombination hold-down and welding fixture, with force / stroke monitoring, shuttle principlenOnline TSD seam trackingnOnline process monitoringnSelective removal of out-of-spec. / critical partsLaserLaserMachineMachineRo
19、botTask Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch19TLC1000 Powertrain Truck Differential Gear“Welding cabin 2x TLC1000 PowertrainTRUMPF Laser TLF12000TRUMPF Laser TLF12000Loading/unloading of welding stations from conveyor via robot systemTask Process Implementat
20、ion: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch20TLC1000 Powertrain Truck Differential Gear“Task Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch21Task: Planet CarrierWelding positionn2-station operationnPre orientation findernInternal loadernFixture with me
21、asuring deviceTask Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch22Task: Planet CarrierLaserMachineWasherInternal loaderPre orientation finderCooling conveyorTurning processTask Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch23Task: Plan
22、et CarrierwasherLaserInternal loaderPre orientation finderSPC and NOKTask Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch24TLC1000 Powertrain Planet Carrier“Task Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch25Compact Beam Delivery for D
23、ouble ClutchTargetnWelding task: Five weldsnAutomation task: Manual load and unload Integration of brushing station Optimized laser utilizationTask Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch26Compact Beam Delivery for Double ClutchSetup with beam sharingLaser on m
24、achine frameTask Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch27Compact Beam Delivery for Double ClutchLayoutnTwo lasers with beam sharing and a total of four weld stations: Three stations with one weld One station with two weldsnDial index table with 4 x 90o includi
25、ng Manual load and unload Clamping tower with integrated spindle Brushing station Reserve stationTask Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch28Compact Beam Delivery for Double ClutchCompact beam deliverywith clamping towerBeam switch with laser and beam deliver
26、yDial index tableTask Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch29Flexible Beam Delivery for Visco DamperTargetnWelding task: Two axial joints in one fixture Flexible change-over for different damper diametersnAutomation task: Transfer system with palettes as carr
27、iers Automated part handlingTask Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch30TLC40 Visco Damper“Task Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch31nTRUMPF TLC 40 + TLF 6000 nNC X-axis for different damper diametersnPalette transfe
28、r system through machine bodynClamping tower with integrated spindle fixed upper toolingFlexible Beam Delivery for “two mass wheel”Task Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch32Palette transfer system through machine bodyClamping tower with lifting stroke and s
29、pindleFlexible Beam Delivery for “two mass wheel”Welding head and part in welding position with fixed upper toolingLifting device with centering pinsTask Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch33TraceabilityTraceability is a characteristic of a process which in
30、cludes the following :Crank shaft / cast steelnCreating data nEncoding datanMarking datanReading datanManaging datanAnalyzing and archiving dataTask Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch34Marking of gear componentsnExamples DC Kassel: bevel gear, crown gearTa
31、sk Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch35Integration in automated production lineTask Process Implementation: Realized ProjectsPrasentationen TRUMPF Vorlage deutsch36TRUMPF servicesnConsulting Laser applications labs Application know-hownService Online suppo
32、rt Telepresence Worldwide connection through SIS Production support Preventative maintenancenTraining TRUMPF training centers worldwide On-site at customersnSpare parts supply 7 x 24 hours Support hotline Spare parts centers worldwide 结束语当你尽了自己的最大努力时，失败也是伟大的，所以不要放弃，坚持就是正确的。When You Do Your Best, Failure Is Great, So DonT Give Up, Stick To The End谢谢大家荣幸这一路，与你同行ItS An Honor To Walk With You All The Way演讲人：XXXXXX 时 间：XX年XX月XX日
