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On-the-Fly Laser Welding
What is On-The-Fly Welding?
On-the-fly (OTF) welding, also known as welding on-the-fly, is an automated laser welding process characterized by continuous motion. An advanced form of scanner welding, this laser welding technique utilizes scanning optics and real-time calculations to account for system motion while ensuring the beam is still directed precisely. Welding while either scanning optics or the target workpiece remain in motion enables a dramatic increase in welding throughput.
Traditional laser welding methods, while often faster than non-laser welding, must come to a stop periodically to make welds. This is true even in the case of traditional scanner welding approaches. By greatly reducing process stops and starts, on-the-fly welding is a powerful technology for maximizing manufacturer productivity when producing both high volumes of small parts and large parts with many individual welds.
On-the-Fly Welding Advantages
Increased Productivity
On-the-fly welding nearly eliminates the "non-productive" time associated with traditional stop-and-shoot laser welding techniques. Welding while remaining in constant motion increases the achievable welds per second and helps maximize throughput.
Improved Reliability
By controlling the scanner's field of view, on-the-fly welding minimizes spot distortion that can impact weld quality. More consistent spots maximize welding process windows to achieve more reliable weld characteristics.
Reduced Operating Costs
On-the-fly welding compensates for system motion to precisely deliver a beam with welding-optimized parameters. Used in combination with real-time weld measurement, on-the-fly welding helps reduce scrap and QA costs.
Uniquely Compatible with Other Productive Welding Technologies
On-the-fly welding relies on real-time calculations and intimate integration between laser optics, motion control, and other system technologies. Traditionally, taking advantage of on-the-fly welding has required manufacturers to sacrifice other advanced welding capabilities.
IPG on-the-fly welding technology is uniquely compatible with productive laser technologies like single-mode AMB dual-beam lasers and LDD real-time weld measurement (patent pending). The combination of these technologies offers manufacturers an unmatched combination of productivity, quality, and quality assurance for demanding welding applications.
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A Key Component in EV & Battery Welding Systems
Utilized by some of the world's largest electric vehicle manufacturers, on-the-fly welding is highly beneficial for the demanding throughput and precision requirements of the e-mobility and battery industry. Working in tandem with other laser welding technologies, on-the-fly welding is particularly powerful for the following applications:
- Battery cell-to-busbar welding
- Lid-to-can welding of battery cells
- Battery cold plate welding
- Bipolar plate welding for fuel cells
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