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AUTOMATED LASER SYSTEMS FOR MANUFACTURING

“I wouldn’t hesitate to use BOS again. Their professionalism and attention to detail made our project go very smoothly – and they built us a good solution. They are problem solvers.”

Engineering Manager

Auto Body Parts Supplier

Laser automation is the process of using robots with lasers to improve industrial applications, such as cutting and welding. This type of automation can enhance efficiency and precision for different kinds of industries.

Automated laser systems combine motion and vision technologies with robotics. The laser can be built in a cell to promote safety and integrated with other automation solutions to meet different needs. Once programmed for a specific purpose, a laser cell can execute a high-quality and accurate work within seconds. Discover how automation can help your business.

Benefits of Laser Automation

Robotic Laser Integration

Often robotic laser systems are the most optimum solution for cutting and certain types of welding. Optimal integration of these systems requires special expertise and BOS is an industry leader when it comes to designing and implementing these cutting edge interfaces.

Laser Safety

Safety is always an issue with laser automation. Our laser safety officer and design team will ensure your system is certified safe, all the way up to and including Class 1 laser enclosures that exceed the demands of laser safety standards. We can build standalone marking and welding systems, right up to enclosures with various types of automatic doors and part loading.

Laser Process Development

If you’re not sure if lasers are right for your production task, we can work with you to get the answers you need. From initial feasibility reviews, to functional testing and complete process development engineering studies, we can provide you with the right data to make informed decisions on automated laser production.

Laser automation control panels

BOS Custom Laser Automation Solutions

From welding and cutting, to marking and surface treatment, add BOS expertise to the process development of your laser based automation application.

Robotic Laser Cutting system

Laser Welding

If you require laser welding, we’ve got the automation solution for you. From medical devices to automotive components and everything in between, we got the experience to provide you with the right laser welding robotics and systems to make your process a success.

Laser Welding on Pallet Line

Laser Cutting

We can design and create automated lasers for cutting nearly any product type, from certain plastics and membranes to most types of metals. If your process requires the use of laser cutting robots, we can engineer and install the right robot for your job.

Dual Robotic Laser Cutting cell

Advanced Manufacturing Solutions

Not sure where to begin? We have proven, modular designs to help get you started. If you need something a bit different, no problem, our experts are available to customize it just for you.

Check out our laser cells for industrial laser cutting or welding:

Past Applications

A lot of what we execute for our customers is confidential or proprietary and cannot be shared publicly. Here is a small sample of past applications to demonstrate BOS' capabilities.

Battery Cooling Plate Laser Welding for Electric Vehicles (EV)

Our customer required aluminum components to be welded together with precision tolerances to assemble battery cold plates for an OEM manufacturer of EV's. 

There were two (2) different part variants. The machine would be manually tended (loaded/unloaded) by operators and had to achieve a part to part cycle time of 36 seconds or less (including operator time).

Traceability of weld quality at the finished assembly level was required. The completed assembly had to pass leak testing.

A 3kW fiber laser and remote welding head from IPG were deployed on a 3-axis linear motion system with direct drive encoders and CNC motion control. The circular welding process required coordinated motion of the remote welding head and the motion system within tight tolerance.

To optimize the cost of the solution for our customer, a single laser cell was utilized with two operators tending separate processes.  One operator tended a drawer/slide and the other tended a turntable. The motion system alternated between these laser processes.  The machine utilized quick-change tooling and a combination of mechanical and digital poka-yokes for part variant control.

An automatic start-up verification procedure was programmed, utilizing a laser beam power meter, to validate laser quality at the start and end of every production shift. Each part received a barcode scan and an impact mark for traceability.

The commissioned laser cell achieved its performance, quality, and safety requirements, including its 36 second part to part cycle time for both welding processes (including operator load/unload time).

Precision 3-Axis CNC Laser Cutting for Truck Side Step Rails

Our customer required 36 holes with tight tolerances to be laser cut in stainless steel rails to create side steps for an OEM truck program.  The ends of each rail also needed to be cut off squarely and without any burrs to accommodate the insertion of a plastic end cap at a downstream process.

There were four (4) different part variants for various wheelbases and cab lengths. The laser cell was to be robotically tended and had to achieve a part to part cycle time of 90 seconds or less (including load/unload).

To achieve the cycle time and precision required, a 2kW fiber laser from IPG and a cutting head from Laser Mechanisms were deployed on a 3-axis linear motion system with direct drive encoders and Beckhoff CNC motion control.

Rotisserie-style trunnion tooling was designed to grip the rail from inside and coordinated motion was utilized to cut each of the holes and complete the end cuts.

The integrated control system allowed for part variant changeover at the push of a button (no manual change-out required).

The commissioned laser cell achieved its performance, quality, and safety requirements, including its 90 second part to part cycle time.

Precision 5-Axis CNC Laser Cutting for Tier 1 Automotive Manufacturer

Our customer required 6 to 12 holes (variant dependent) with tight tolerances to be laser cut in octagonal steel tubes with variable wall thickness to create a component for an OEM automotive program. One end of each tube needed to be cut off at a 21.5 degree angle.

There were two (2) different part variants. The laser cell was to be robotically tended and had to achieve a part to part cycle time of 40 seconds or less (including load/unload).

To achieve the cycle time and precision required, 5-axes of CNC motion control were coordinated with a trunnion positioner. A 1kW fiber laser was deployed on a rotary cutting head to allow for the range of motion required to complete the 21.5 degree and cuts.

Complex tooling was required that could slide and re-datum the part mid-process. The sequencing could not affect the repeatability of the cutting process.

Laser focal length and cutting power were optimized throughout the process to accommodate for the variable wall thickness of the octagonal tube. 

The integrated control system allowed for part variant changeover at the push of a button (no manual change-out required).

The commissioned laser cell achieved its performance, quality, and safety requirements, including its 40 second part to part cycle time.

This was one of the first pre-engineered L-MS laser cells integrated for a customer.

LEARN MORE ABOUT AUTOMATION

Contact us today and see how we can help you automate your business. 

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