en.Wedoany.com Reported - EMAG LaserTec has launched the standardized laser welding system ELC 6i, targeting high-volume production needs of powertrain component manufacturers, with the goal of enhancing process reliability while reducing equipment costs and floor space.

The machine integrates up to six process steps into a single automated workflow, covering laser cleaning, assembly, welding, and marking. By replacing multiple dispersed machines with an integrated platform, the production line is streamlined, and investment costs as well as engineering efforts are reduced.

The development of the ELC 6i leverages EMAG's experience accumulated across numerous laser welding projects, with its functional configuration focused on the most commonly used manufacturing processes. Instead of customizing for individual applications, EMAG adopted a standardized design to reduce system complexity and shorten implementation cycles.

Daniel Rujanoski, Global Sales and Application Director at EMAG LaserTec, stated: "The ELC 6i reduces engineering expenses through standardization, delivering high returns for customers. For products with large batch sizes and clear repetitive demand, unit costs and delivery times can be significantly reduced."

Compactness is a standout feature of this system. The machine occupies approximately 21.5 square meters and can accommodate up to six process stations. EMAG states that compared to conventional production line solutions, its space requirement can be reduced by more than 30%.

The machine structure features a central rotary indexing conveyor, equipped with an integrated laser safety enclosure and standardized processing modules. The workpiece carrier transport system accommodates up to 18 workpiece carriers, advancing two components per cycle to enable parallel operation, with cycle times controllable within 20 seconds.

Workpieces pass sequentially through the loading/unloading station, laser cleaning, optional induction preheating, servo-mechanical assembly, laser welding, and optional laser marking for traceability. All processes are integrated into a single automated workflow without requiring manual intervention.

Laser cleaning uses oscillating optics for selective treatment; the optional preheating process enhances process stability and reduces stress before assembly or welding. The assembly step is monitored through a force-displacement controlled pressing process; welding employs circumferential laser welding technology with weld seam position control sensors.

The welding station follows the proven ELC 6 machine concept, which EMAG states has been applied in hundreds of systems worldwide. Precisely positioned laser optics and additional workpiece positioning axes provide the accuracy required for demanding powertrain machining.

The standardization approach also delivers economic benefits. According to EMAG estimates, investment costs can be reduced by up to 15% compared to customized production lines; delivery times can be shortened by up to 20% through the use of proven designs and reusable software modules.

The system replaces multiple independent control units with a single Siemens Sinumerik One CNC central control system, reducing software complexity and simplifying programming, commissioning, and maintenance. The use of standardized components also improves spare parts availability and maintainability.

The ELC 6i targets manufacturers with annual production volumes exceeding 100,000 units, balancing high-volume production with flexibility. Similar components can typically be processed without changeover; when adjustments are required, they generally involve only tooling and clamping systems, which can be completed within 20 minutes.

Rujanoski said: "The ELC 6i is the culmination of decades of project experience, focusing on core elements and consistently designed around efficiency, quality, and cost-effectiveness."

In terms of customer support, EMAG's laser application center in Heubach, Germany, provides application development, prototype sample production, and production launch support, helping customers complete process development and optimization before large-scale production begins.