Our engineers developed a process that significantly improves OTD: Controlling the intensity of light in laser welding.

The challenge:

Accurate and proper welding is crucial for the product’s strength and performance.

• The laser’s welding power depends on the laser lamp’s power—which intensity decreases with use, resulting in a decrease in power at the welding point.
• Despite the change in power, measuring it in the welding machine’s control is impossible.
• Also, the control over the obsolescence of the lamp is insufficient. There is no single-value definition for replacement time.
• Welding without regard to the variations in lamp power means varying and uncontrolled results—leading to disqualifications, extended OTD, and costs increase.

The solution:

• The motor developers determine the optimal laser power for welding the parts. It is measured by an external device (Vega) that gives a numerical value to the desired power.
• When performing the first welding approval in an external test, the Vega measures the laser beam’s intensity.
• The developers record intensity parameters in the execution instructions of the particular weld.
• The Vega monitors the laser intensity through the step.
• In serial production, engineers repeat the parameters, including control parameters.

This process ensures that the welding is carried out at the same intensity, regardless of the lamp’s condition. The welding process is stable, and each batch’s results are expected and identical.

The benefits: Minimal disqualifications lead to consistent OTD and cost reduction.