en.Wedoany.com Reported - Han's Laser Intelligent Equipment Group has launched a high-power laser welding solution targeting process pain points in the welding of automotive transmission components, covering key parts such as clutches, differentials, gears, and flexible flywheels, and providing one-stop services from process solutions to production line integration.
As automotive manufacturing evolves toward precision, efficiency, and lightweight design, the welding quality of transmission components directly impacts vehicle stability and service life. Components such as clutches, differentials, and transmission gears commonly face challenges in welding, including high process difficulty, diverse materials, stringent defect control, and demanding appearance and sealing requirements. Most welds are annular structures, and control of welding deformation and precision heavily relies on specialized processes and precision fixtures.
Han's Laser's high-power laser welding technology features a small heat-affected zone, controllable welding deformation, excellent weld depth-to-width ratio, and high automation. For clutch welding, this solution employs a ring-shaped spot laser autogenous welding process, suitable for butt circumferential welds between the housing and shaft, with post-weld concentricity controlled within 0.10 mm. The production line integrates automatic slag removal, online weld inspection, data collection and traceability, process monitoring, and remote maintenance systems, achieving full-process automation from loading, welding, grinding, and marking to unloading.
For differential welding, a filler wire welding process is used, suitable for butt radial and axial circumferential welds between the differential case and the driven gear. The welding process simultaneously clamps the workpiece to ensure weld fit and stability. This process eliminates the need for bolts and corresponding steps, reduces the size and thickness of the load-bearing flange, achieving weight reduction and compact structure. Additionally, welding deformation is minimal, tolerances are controllable, and the weld can withstand higher torque while reducing transmission noise.
To ensure consistency in welding quality, Han's Laser has also built an automated differential welding assembly line, integrating full processes such as laser cleaning of the differential case, laser cleaning of the back teeth, gear heating, hot assembly of the large differential case, hot pressing of the small differential case, resistance torque detection, laser welding, and weld grinding, achieving full-process automated precision manufacturing from component pretreatment to finished product output.
For transmission gear welding, the transmission gear consists of a ring gear and a gear ring, using a deep penetration laser welding process. The equipment integrates processes such as gear cleaning and drying, pressing, preheating, laser welding, and online inspection, achieving a weld depth of ≥5 mm and a depth-to-width ratio of ≥3. During welding, shielding gas is added to protect the molten pool, and a weld quality monitoring system is configured for real-time status monitoring. Through online monitoring and ultrasonic inspection, weld depth and defects such as porosity are precisely controlled, with strict post-weld control of coaxiality and end face runout. Flexible flywheel welding adopts a fully automated assembly and processing solution, with automatic loading and unloading for each process, effectively improving equipment automation, yield, and production efficiency. This process requires a weld depth of ≥3 mm, no cracks, no pores with a diameter greater than 0.5 mm, and minimal welding deformation, balancing connection strength and appearance quality.
Additionally, Han's Laser's high-power welding technology can also be adapted for welding various other transmission-related components such as pistons, steering columns, crash boxes, turbochargers and valves, silicone oil dampers, and shift forks. Han's Laser Intelligent Equipment Group has established vertical integration capabilities in the laser and automation field, from core components and complete equipment to process solutions. Its high-power welding technology has fully covered Automotive Industry" target="_blank">new energy vehicle motors, batteries, structural parts, cover parts, body-in-white, seats, transmission components, and other parts, forming a capability system covering multiple scenarios in automotive manufacturing.
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