Development of new portable laser welding machine

The result of the project is a portable welding device that will be much lighter, more flexible and easily transportable across the stairs. The device will be made of several components, of which none will exceed e.G. 50 kg. The device will use a new generation of lasers (fibre lasers).

The result of the project will be a portable laser device, providing for mobile welding in a simple way. As a source of a laser beam, the fibre laser of average power around 300 W will be used, which is enough for fast work. The laser source will always be equipped with pulse shaping. A pulse will be shaped in a simple and user-friendly way through a computer programme. Due to small moving masses, the optical part will be made of light metals, for example from magnesium or carbon fibres. On the optical unit, LED illumination will already be installed at four places by lens, which will be additionally adjustable and will enable setting of the illumination level. In this way, one holder will be avoided, which otherwise represents additional mass (weight) and disturbs the welder while welding. A camera will also be a part of the optical unit, substituting the eyepiece as well as contributing to even lesser mass of the optical unit. In addition, optics will be smaller and hence more appropriate for welding in large tools. Moreover, the optical unit will also be equipped with an auxiliary laser system for finding a focus as well as an integrated supply of shielding gas to the welding point. Optical control will take place by means of a control lever. The guides, on which the optical unit will be fixed, will be equipped with a magnet, providing for a simple fixation of the device on a tool. The laser device will also provide for production of contours. This means that the device can be taught which route it should follow by inserting the points. Then, it would connect the points and follow the route. Software will obviously enable making of circles, arcs and guidance from one point to another following the linear interpolation system. To make the work easier, the programme will also make offset circles with a smaller or a larger radius. This is a three-dimensional learning of the laser route. The laser device will be build in the way to enable additional installation of the system for the welding wire supply. In this case the device will also be ready for remote work. This means that on foundry or injection machineries, where there are high temperatures, welding can take place without any direct presence of an operator for the device or the latter can be located somewhere by the machine, where the work conditions are much better. The foreseen masses of individual parts of the device are, as follows: - laser beam source aroundl48 kg, - optical unit with illumination 2.5 kg, - control unit with the power supply around 25 kg. The above-indicated mases are reachable, which means that the total mass of the portable device will be below 80 kg. The mass of the lightest mobile laser of the same power (300 W) at the moment is 320 kg. Therefore, in our case the use of the name “portable laser” rather than “mobile laser” is justified: mass in comparison with the competition is lower by 75%. Since these three units will be packed in separate suitcases they can be loaded in a passenger car. The main goal in production will be light construction and integration of individual subsystems. The mobile laser devices exist, while the modular still do not, but there are market needs. In the market, several mobile devices exist, but their masses are quite big: between 340 and 920 kilograms, so the word “mobile” is not really appropriate. Fundamentally, the mobile laser devices are intended for welding in a workshop and not for work in the field, in storeys, on walkways (foundry machineries and machineries for plastics injection). If the damaged tool was welded, for example, on a foundry machine, the repair would take only a few hours and not four days, which is the case in repairs with the classical arc welding processes. This would be considerable saving of time and money, especially in cases of three-shift work. The main markets are: foundries of non-ferrous metals, manufacturers of plastic parts, tool repair workshops, pharmaceutical industry, manufacturers of turbine and water pumps, etc. Of course, each portable or mobile laser may also be stationary at the same time. Therefore, buyers of the mentioned device may also be buyers of usual stationary systems.
Project ID: 
11 210
Start date: 
Project Duration: 
Project costs: 
930 000.00€
Technological Area: 
Jointing (soldering, welding, sticking)
Market Area: 

Raising the productivity and competitiveness of European businesses through technology. Boosting national economies on the international market, and strengthening the basis for sustainable prosperity and employment.