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One trend that has been consistent for years in the automotive industry is that passenger vehicle transmissions are becoming smaller and lighter, although the number of toothed gear components and speeds keep increasing. The reason for the entire assembly remaining lighter becomes obvious by taking a closer look at the individual components. For example, a gearwheel consists of two components that are joined by laser welding. This enables the design engineers to work without screws — enabling the components to become lighter.
Integrating Laser Welding into the Production System
The advantages mentioned above explain why laser welding has become an integral process in transmission manufacturing. However, it is not possible to easily integrate this method into a complete production line because the actual laser welding process is preceded and succeeded by many other processes. Based on the component, these may include checking, washing, joining of components prior to laser welding, a brushing process, and a final ultrasonic inspection of the welding seam.
EMAG developing multi-stage production solutions
Implementing comprehensive production lines that integrate laser welding into the overall sequence—is the special expertise of EMAG Automation. We are very familiar with the production sequence for central transmission components. Therefore, we do not just design another laser welding machine. With our multi-stage production solutions, we focus on creating a perfect process chain that operates quickly, and very safely.
Dr. Andreas Mootz, Managing Director of EMAG Automation
EMAG’s specialists from Heubach near Schwäbisch Gmünd, Germany perfectly customized every detail of these systems to the component. Considering inspection methods as an example, EMAG Automation has developed its own ultrasonic inspection method.
The trend goes toward zero-defect production that ensures the quality of every single welding seam. We can guarantee it with this technology.
Dr. Mootz
ELC series—a success story in transmission manufacturing
Obviously, the laser welding machine itself is also perfectly configured. It is always a tailored solution, and based on the ELC series machines each model is ideally suitable for different types of components. For instance, the ELC 160 HP machine is a unique solution for gearwheels, whereas the ELC 160 model offers an all-round solution for many automatic transmission and dual clutch components. The cooperation between EMAG Automation and EMAG Maschinenfabrik in Salach is another major success factor. By integrating their resources, they can implement the complete production sequence for transmission components—from welding to turning and grinding.
In this way, production planning has become so much easier. This is a huge benefit that is continually increasing its market recognition.
Dr. Mootz
This information has been sourced, reviewed and adapted from materials provided by EMAG LLC USA.
For more information on this source, please visit EMAG LLC USA.
Laser Welding for Transmission Manufacturing Applications
Laser Welding for Transmission Manufacturing Applications