EMAG LaserTec has introduced the ELC 6i, a standardised laser welding system designed to help powertrain component manufacturers reduce costs, save floor space and improve process reliability in high-volume production environments.
The new machine combines up to six process steps within a single automated system, including laser cleaning, joining, welding and marking. By replacing multiple standalone machines with one integrated platform, EMAG aims to simplify production lines while reducing investment and engineering costs.
Developed from the company's experience across numerous laser welding projects, the ELC 6i focuses on the most commonly required manufacturing functions. Rather than creating bespoke solutions for every application, EMAG has adopted a standardised approach intended to cut complexity and speed up implementation.
Daniel Rujanoski, director global sales and Applications at EMAG LaserTec, said: “With the ELC 6i, we offer a laser welding system that provides high customer benefits with reduced engineering costs through standardisation. Unit costs and delivery times can be significantly reduced, especially for large quantities with recurring requirements.”
A major feature of the ELC 6i is its compact footprint. The machine occupies around 21.5m² while accommodating up to six process stations. According to EMAG, this can deliver floor space savings of more than 30% compared with conventional line concepts.
The compact design incorporates a central rotary indexing conveyor, integrated laser safety enclosure and standardised handling modules. Components are transported through the machine on a transfer system holding up to 18 workpiece carriers. Two parts advance with each cycle, allowing parallel operations and cycle times of less than 20 seconds.
Within the system, workpieces pass through loading and unloading stations, laser cleaning, optional inductive preheating, servomechanical joining, laser welding and optional laser marking for traceability. All stages are integrated into a single automated process requiring no manual intervention.
Laser cleaning is carried out selectively using oscillating optics, while the optional preheating stage is designed to improve process stability and reduce stresses before joining or welding. Joining is monitored through a force-displacement controlled pressing process, and welding is completed using circumferential laser welding technology supported by seam position control sensors.
The welding station is based on the proven ELC 6 machine concept, which EMAG says is already used in hundreds of systems worldwide. Precisely positioned laser optics and additional workpiece positioning axes are intended to provide the accuracy required for demanding powertrain applications.
EMAG also highlights the economic benefits of standardisation. The company estimates investment costs can be reduced by up to 15% compared with customised production lines, while delivery times may be shortened by as much as 20% through the use of established designs and reusable software modules.
A central Siemens Sinumerik One CNC control system replaces multiple separate controls, helping to reduce software complexity and simplify programming, commissioning and maintenance. The use of standardised components is also expected to improve spare parts availability and serviceability.
Targeted at manufacturers producing more than 100,000 components annually, the ELC 6i is designed for high-volume production while retaining flexibility. Similar components can often be processed without changeovers, while any required adjustments are typically limited to tooling and clamping systems and can be completed in less than 20 minutes.
“The ELC 6i is the result of decades of project experience, focused on the essentials and consistently designed for efficiency, quality and cost-effectiveness,” said Mr Rujanoski.
To support customers, EMAG offers application development, prototyping and production launch assistance through its Laser Application Center in Heubach, Germany, where processes can be developed and refined before full-scale production begins.