Solutions
When TRUMPF launched the TruLaser Weld 5000 and FusionLine function in 2016, they reduced the previously stringent requirements for part accuracy required for laser welding. FusionLine makes it possible to compensate for inaccuracies in a part, such as those resulting from a previous bending process. This allows parts to be joined even if they haven’t been optimised for laser welding. FusionLine easily seals gaps up to one millimetre wide. Switching between FusionLine and traditional laser welding methods, like heat conduction and deep penetration welding, is possible without retrofitting the system. "We hesitated for a long time to venture into automated laser welding, primarily due to the high demands in terms of part preparation," reflects Kevin Kempf. "TRUMPF removed this hurdle when it launched FusionLine."
Another aspect that had long commanded the brothers' respect was the fixture setup, which previously required intensive milling and the addition of copper plates for heat dissipation. "If you tell a customer that the fixture for a single part costs a few thousand euros, they'll dismiss the idea," says Kevin Kempf. But here, too, times have changed. Today, modular sheet metal fixtures and reusable standard clamping systems are more than sufficient. We were confident we could build the sheet metal fixtures ourselves," Marcel recalls. Kevin adds with a grin, "It wasn't easy at first, but we got there in the end."
The TruLaser Weld 5000 features a dual station table that allows for high-speed welding of large quantities at Kempf, operating parallel to production. "The machine is so fast that we spend considerably more time on preparation than the system does on the actual welding process," says Kevin Kempf. At Kempf, the rotate and tilt positioner is used for the two-sided processing of parts, particularly for welding more complex parts. "We had components that took over an hour for TIG welding and the necessary post-processing. Using laser welding, we can complete them in just ten minutes. The TruLaser Weld 5000 allows us to accomplish in a single shift what would have previously taken an entire week", Kevin Kempf sums up enthusiastically.
Implementation
The Kempf brothers have come up with a neat idea to get a grip on their machine utilisation rate. "Initially, our employees showed little enthusiasm for redesigning parts for automated welding and building the required fixtures. That's when we came up with the idea of awarding a bonus for each part they managed to optimise for laser welding. I need an NC program, the appropriate fixture and documentation of the new process – in other words, how it was before and how it can be done now. And of course, we need the customer's approval," says Kevin Kempf. "If an employee accomplishes this, they receive a bonus." The plan is effective – employees quickly identify numerous parts suitable for laser welding, work on the programming, and design and construct the fixtures.
An increasing number of customers are now keen to use the technology. "Once customers have their parts redesigned for the process and have witnessed a laser weld, nothing else will do. They realise that the process represents a significant leap in quality compared to MIG, MAG and TIG welding, especially when it comes to manual welding," explains Marcel Kempf. Another decisive factor is that the TruLaser Weld 5000 not only processes orders quickly and punctually, it also delivers 100% reproducible welding results at all times. "That's the kind of reliability our customers appreciate," says Marcel Kempf.
