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The Essential Role of Fixture Design Continued from previous page
reliability of the final product. This requirement is particularly vital in aerospace and EVs, where safety and performance are paramount. Imagine an aerospace com-
ponent with a slight gap between two critical parts due to inade- quate fixture design. These gaps can lead to stress concentrations when exposed to rigorous flight conditions, causing premature component failure. In the EV sec- tor, where battery packs are assembled using laser welding, any gaps or misalignment in the components can affect the over- all performance and longevity of the battery, potentially leading to costly recalls. These gaps also lead to a fail-
ure mode where the weld acts as a hinge flexure, subjecting it to stress and ultimately causing weld failure over time. Further - more, such gaps can serve as col- lectors of oxides and contami- nants, leading to further oxidation of the weld from its backside.
Registration and Tolerances Maintaining consistent reg-
istration and tight tolerances between components is another crucial function of a well- designed fixture. In precision- critical industries such as med- ical devices and automotive, even minor variations in align- ment can result in unacceptable product deviations and increased reject rates. Fixtures must ensure that parts are securely held in their intended positions throughout welding. Tolerance plays a vital role in both the fix- ture and the components. Unacceptable component
tolerance stack-ups can lead to mispositioned components, part gaps, over- or under-clamping of the element within the fixture, and overall yield issues in the laser welding process. It should be noted that various clamps may be needed, and the setup of these clamps becomes critical. All that is needed is a slight
preload to keep the parts in a fixed position and the overall fix- ture in place.
Alignment In laser-based welding
applications, maintaining an unobstructed path for the laser beam is evident and crucial for achieving precision. With a vari- ety of off-the-shelf welding opti- cal heads, manufacturing engi- neers need to be aware of the characteristics of the laser beam output of the lens within that focusing head. The collimated beam diameter received at the focus lens, the cone angle output, the working distance of the focusing lens, and the spot size on the target all play a vital role
Want to see these systems in action? Join us at APEX, April 9-11 and experience the future of component reel future of component reel management firsthand. Take advantage of the opportunity to revolutionize your
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in the laser material interaction during welding. Once the welding parame-
ters are established, initial test- ing parameters can be brought to the laser machine tool. The design of the fixture must take into consideration several factors for proper laser welding, includ- ing nozzle gas pressure, nozzle end size, the reflectivity of the material being processed, the angle at which the laser focus head is angled to eliminate back reflections, and the observed
Page 55
visual alignment verification to ensure the accuracy of the weld- ing process. Fixtures must provide clear
access for the laser beam to reach the welding zone and enable operators to verify compo- nent alignment through cameras or other machine vision optical systems. These openings must also ensure that the welding spatter can eject and that those openings can be cleaned easily.
A typical lever clamp to fix the pallet fixture in place.
In the automotive industry, Continued on page 57
Want to see these systems in action? Join us at productronica on November 14-17, 2023 and experience the management first hand. Take advantage of the opportunity to revolutionize your inventory management and
Munich, November 14-17, 2023 Hall A3, Stand 103
Anaheim, CA, April 9-11 Booth 3300
See at IPC APEX, Booth 3300
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