Challenges

A variety of welding processes, combined with well trained professionals – Böhmer Systemtechnik GmbH was a true master of welding competence. Just one thing was missing: laser welding. CEO and special welding engineer Josef Böhmer has been intrigued by the technology for a long time, but he also knew that it needed the right parts. When TRUMPF offered him the large-format TruLaser Weld 5000 laser welding system on a trial basis, there was no question about it. "There are not a lot of companies out there with the experience, expertise and necessary machines for welding large parts with a laser. That is exactly where I saw our opportunity."

Solutions

Thanks to XXL laser welding, Josef Böhmer is killing two birds with one stone: he has extended his product portfolio and enhanced his welding competence. Böhmer is impressed, "It is a real advantage if you have an eye for which parts are suitable for laser welding. We believe that laser welding is a consistent and important addition to other processes, but it also opens a whole range of new opportunities." The company uses the TruLaser Weld 5000 mainly for welding parts for concrete formwork with long seams, as well as for thin sheet parts for caravan construction. Low production tolerances paired with maximum stability are needed for the first sector, the latter requires a visually pleasing seam. The laser welding system manages this balancing act.

Implementation

The flexibility of the system is an important bonus of laser welding for Josef Böhmer. "We work with a Kuka robot on a linear axis and a turnover positioner. This means that we can cover a large work area, four meters long and 1.20 meters wide." A crane in the machine makes life easier for the employees when lifting heavy parts. The rotate and tilt positioner of the TruLaser Weld 5000 is a big help if a small part needs to be welded in the meantime. Böhmer explains, "We can use it to weld small parts without first removing a fixture for larger parts from the turnover positioner." In addition, the rotate and tilt positioner makes it possible to weld parts which are difficult to access in just one setup thanks to its NC rotary axis integrated in the robot control.

Forecast

Böhmer is initially processing batches of 25 to 50 units on the TruLaser Weld 5000, larger batches are planned in future. The prospects are good, says Josef Böhmer. "We often have queries about laser welding when it comes to new parts. Customers rely on our wide-ranging welding competence – with good reason." Processes can be planned more efficiently with the automated laser welding system. This has a positive effect on delivery times – and on customer satisfaction. Josef Böhmer is also satisfied, "We can extend our portfolio even further with this machine, ensuring our company's success in future as well. It is already obvious that the investment will pay for itself."