ThyssenKrupp Implements IDEAL Laser Welder into Existing HDG Line
03/20/2015 - The implementation of a laser welding machine into an existing hot dip galvanizing line (HDGL) a ThyssenKrupp in Germany (TKSE) set an example for IDEAL’s unique solutions.
Since 1923 the name IDEAL has stood for innovation and progress in the production of welding & automation solutions. In addition to standard machines, IDEAL designs and manufactures tailor made machines, according to the particular demands of the welding task.
In the range of coil joining procedures, IDEAL offers solutions based on the technologies butt welding, flash but welding, shield arc welding and laser welding.
IDEAL laser welding machines was developed to fulfill the increasing market demands in coil joining application for high quality expectations. The key facts are joining with weld seams without over-thickness, the joint need to withstand all subsequent processes such as rolling and deep-drawing, high-quality steel of high strength or high silicon content have to be processed and coated materials have to be joined. The machines are used in inspection lines, slitting lines, galvanizing lines, organic or multilayer coating lines, pickling lines, continuous annealing lines and rolling mills.
Motivation
The new, high sophisticated steel grades such as AHSS, dual and TRIP steels are more and more a challenge of getting them joined in current and future steelworks’ processing lines. The partly built-in technologies like flash butt welding and overlap welding are just not able to cope with these particular grades anymore.
Challenges
Looking at the above the driving factor of implementing a laser welder into an existing line was to get away from the need of having to weld intermediate mild steel strips between the AHSS coils (ZEBRA System). The IDEAL concept takes well care of that particular problem as not only the joining of the coil head to the tail is done by the laser also the strip end preparation is realized by means of laser cutting, which provides an outstanding strip edge preparation and that right through the different range steel grades. Even different material mix as well as various strip dimensions and eventually coatings can now be managed.
The second challenge for such a HDGL is the space availability. Here IDEAL had to find a solution of squeezing in a machine into a quite narrow footprint. The 3D modeling tool was of great help to solve this particular task. Beside of the space availability IDEAL also had to face a substantial number of obstacles like supporting beams, columns pipes, etc. and that in all directions. Even in height there were restrictions as there is an oven platform just above the welder.
Third, but not least was the very short commissioning period as it is usually the case for projects of line revamping. TKSE and IDEAL have mutually worked out a tight schedule as well as an assembly procedure for keeping the commissioning period as short as possible.
Result
The result was a customized solution, which is taking care of a full continuous work flow in the TKSE plant.
In the range of coil joining procedures, IDEAL offers solutions based on the technologies butt welding, flash but welding, shield arc welding and laser welding.
IDEAL laser welding machines was developed to fulfill the increasing market demands in coil joining application for high quality expectations. The key facts are joining with weld seams without over-thickness, the joint need to withstand all subsequent processes such as rolling and deep-drawing, high-quality steel of high strength or high silicon content have to be processed and coated materials have to be joined. The machines are used in inspection lines, slitting lines, galvanizing lines, organic or multilayer coating lines, pickling lines, continuous annealing lines and rolling mills.
Motivation
The new, high sophisticated steel grades such as AHSS, dual and TRIP steels are more and more a challenge of getting them joined in current and future steelworks’ processing lines. The partly built-in technologies like flash butt welding and overlap welding are just not able to cope with these particular grades anymore.
Challenges
Looking at the above the driving factor of implementing a laser welder into an existing line was to get away from the need of having to weld intermediate mild steel strips between the AHSS coils (ZEBRA System). The IDEAL concept takes well care of that particular problem as not only the joining of the coil head to the tail is done by the laser also the strip end preparation is realized by means of laser cutting, which provides an outstanding strip edge preparation and that right through the different range steel grades. Even different material mix as well as various strip dimensions and eventually coatings can now be managed.
The second challenge for such a HDGL is the space availability. Here IDEAL had to find a solution of squeezing in a machine into a quite narrow footprint. The 3D modeling tool was of great help to solve this particular task. Beside of the space availability IDEAL also had to face a substantial number of obstacles like supporting beams, columns pipes, etc. and that in all directions. Even in height there were restrictions as there is an oven platform just above the welder.
Third, but not least was the very short commissioning period as it is usually the case for projects of line revamping. TKSE and IDEAL have mutually worked out a tight schedule as well as an assembly procedure for keeping the commissioning period as short as possible.
Result
The result was a customized solution, which is taking care of a full continuous work flow in the TKSE plant.
