Laser material processing at Bosch: trends, challenges and

Transcription

Photonics 21 - WG2
Laser material processing at Bosch:
trends, challenges and perspectives
Robert Bosch GmbH
Corporate Sector Research and Advance Engineering
1
CR/APJ2 | 30.04.2013 | © Robert Bosch GmbH 2013. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion,
Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
Dr. Jens König
Photonics 21 - WG2
Outline


2
Application review
 Laser in the Bosch production
 Successfully implemented applications
Trends in focus topics
 Laser welding & joining
 Laser micro processing

Challenges & Perspective

Summary
Photonics 21 - WG2
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2008
2001
1997
1992
1988
1985
1981
1976
Application review
Photonics 21 - WG2
Trimming on ceramic substrate
Speed sensor
with CO2 (1983)
2008
2001
1997
1992
1988
1985
1981
1976
Application review
Injection valve, solenoid
armature/seat holder, pw (1984)
Aluminum fuel filter (1994)
Lasers have been used successfully at Bosch for more than 35 years
4
Photonics 21 - WG2
2008
2001
1997
1992
1988
1985
1981
1976
Application review
Cut
Inscribing and marking
Hardening of components in starter drive
Laser soldering
5
Photonics 21 - WG2
Precision cutting and drilling
Plastics welding
2008
2001
1997
1992
1988
1985
1981
1976
Application review
Escape groove, ultrashort
pulse machining (2008)
6
Photonics 21 - WG2
Lasers in current Bosch applications
20
Lasers for welding in the Bosch production
CAGR~20%
15
10
5
year
Laser for micro processing applications
 Number of lasers (only picosecondpulse duration) increased by
a factor of 4 between 2009 and 2012
 CACR expected for next years ~ 40%
 Strongest growing laser field
CAGR = compound annual growth rate Pav = average laser power
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CAGR~40%
15
20
13
20
11
20
09
20
07
20
05
20
03
20
01
20
99
19
97
19
95
0
19
Lasers for welding apps. in
relation to 1996
Laser for metal welding applications
 Number of lasers increased by
a factor of 15 between 1996 and 2011
 CAGR over the last 15 years ~20%
 More than 90% of all welds are
carried out with solid state lasers
with an average power Pav < 1 kW
Photonics 21 - WG2
Laser welding in typical Bosch products
8
Direct gasoline pressure pump
7 laser welds
Direct gasoline piezo injection valve
19 laser welds
intake-manifold injection valve
6 laser welds
Transmission control unit
more than 50 laser welds
Direct gasoline injection valve
7 laser welds
ABS8/ESP8
more than 39 laser welds
Photonics 21 - WG2
Laser micro processing in typical Bosch products
Broad band lambda Probe
Trimming structures
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Diesel injector 1800 bar
Drainage groove
Direct gasoline injection valve
Spray holes
Photonics 21 - WG2
Outline


10
Application review


Summary
Photonics 21 - WG2
Global trends
Trends in products

Volatility of markets
 Dynamics in variants
 Dynamics in demands
 Dynamics in product live
cycle
Trends in production




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Function increase
 Miniaturization
 Lightweight
Digital product development

Flexible production
 Modularization concepts
 Individualization at end of
process chain
 Scalable production
Material & precision
 Multi-material mix
 Functionalized materials
 Precision requirements
Simulation Tools
Photonics 21 - WG2
The IIW White Paper – R&D needs
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The IIW White Paper; Improving Global Quality of Life Through Optimum Use and Innovation of
Welding and Joining Technologies; International Institute of Welding 2012
Photonics 21 - WG2
The IIW White Paper – Hot topics
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The IIW White Paper; Improving Global Quality of Life Through Optimum Use and Innovation of
Welding and Joining Technologies; International Institute of Welding 2012
Photonics 21 - WG2
Trends: laser micro processing
Source: Prof. Dr. Poprawe RWTH Aachen
Production System
Customer individualization at end of process chain
by flexible ablative laser processes
in finishing process
Dynamic
decision
unit
Supplier
…
Supplier
Supplier
Customer individualization in process
chain by joined modular components
CPE: Cyber Physical Engineering // CPS: Cyber Physical System
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Photonics 21 - WG2
Outline


15
Application review


Summary
Photonics 21 - WG2
Challenges in welding & joining
miniaturisation
higher local loads
function integration
materials
high strength
steels
fiber reinforced
plastics
lightweight
Aluminium (Al)
power electronics
Copper (Cu)
e-mobility
e-drive efficiency
magnetic
materials
* GFR: glass fiber reinforced plastics
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combinations
High strength
steels
Composites
(GFR*) - steel
Composites
(GFR*) - Al
Al -Steel
Al -Al
Al -Cu
Cu -Cu
electrical
sheets
Structure Simulation
Enabler for fast development
push factors
Photonics 21 - WG2
Challenges in laser micro processing
Average power of
ultra short pulsed laser systems
[Nolte et. al.; „Faserlaserkonzepte für UKP-Strahlquellen“ ; UKP-Workshop (2011)]
Scientific
Industrial
Strong increase of laser power
(by a factor 10 in 5 years)
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Productivity increase
lower than
increase of laser power
Main Limitations:
 system technology
(e.g. scanner speed for pulse
repetition rates)
 thermal load on workpiece
Target:
Productivity increase by
factor 50
Photonics 21 - WG2
Main development needs
1) Reduction of invest costs - Laser systems & optical system technology
(scanner, heads, security equipment, ….)
2) Simulation tools - Structure simulation (FEM) & material (synthetic material data)
& process (usable tools based on standard solver)
3) Quality assurance - monitored processes  close-loop controlled processes

“Intelligent optics” for close-loop control (or measurement) of

Focus position related to workpiece (including thermal shift; ~ 0,5 zR)

Power at workpiece (including debris on protective glass; ± 3% RMS)

Intensity distribution at workpiece (differences > 10%)
4) Productivity & usability in laser micro processing - scanner / beam steering
technologies & ultra short pulsed laser systems > 300 W – transport fibers
5) Increase of wall-plug-efficiency - especially for brilliant lasers (BBP ≤ 4 mm·mrad)
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Photonics 21 - WG2
Outline


19
Application review


Summary
Photonics 21 - WG2
Summary
Laser material processing will be a „hot topic“ in the
future
Invest costs of laser equipment is the highest barrier
(and in most cases showstopper for laser processes)
Simulation tools (structure, material, process) are
necessary for shorten time to market and
enabling full potential of laser processes
Picures: wikipedia.org; Erwin Wodicka - wodicka@aon.at
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Photonics 21 - WG2
Thank you
for your attention
Dr. Jens König
Robert Bosch GmbH
21
Corporate Sector Research and Advance Engineering
Laser material processing, electronic packaging and interconnection technology (CR/APJ)

Laser material processing at Bosch: trends, challenges and

Transcription

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