In the production of powertrain components, companies are under increasing pressure to manufacture more economically, space-saving, and process-reliable – especially for high quantities and price-sensitive projects. The new ELC 6i from EMAG LaserTec is designed as a consistent response to these requirements. It integrates up to six process steps around laser welding in a single, standardized system, significantly reducing complexity, space requirements, and investment costs.
Standardized complete solution for automated process chains
The ELC 6i is based on the experiences from numerous realized laser welding projects at EMAG. The goal was to create a repeatable system concept that encompasses all essential steps – from cleaning to joining, welding, and marking – in a single machine. The ELC 6i deliberately omits unnecessary options and focuses on exactly the functions needed in most applications.
Daniel Rujanoski, Director Global Sales & Applications at EMAG LaserTec, explains:
"With the ELC 6i, we offer a laser welding system that provides high customer benefits through standardization while reducing engineering costs. Especially for large quantities with recurring requirements, this significantly reduces piece costs and delivery times."
Compact design – up to 36% less space required
The space requirement of industrial production lines is a crucial economic factor. The ELC 6i combines up to six stations on an area of only about 21.5 m². Compared to conventional, individually designed line concepts, this results in savings of over 30%. This compactness is achieved through continuous layout planning with a central circular conveyor, integrated laser safety enclosure, and standardized handling modules.
The transfer system with up to 18 workpiece carriers moves the components through all stations at a fixed pace. Two components are transported per cycle, allowing for parallel processes and very short cycle times of under 20 seconds.
Integrated process flow for maximum efficiency
The ELC 6i represents a complete process chain within a single system:
• Loading and unloading: Two stations each for placing and removing the workpieces
• Laser cleaning: "Selective" cleaning of both component partners using laser, guided by a pivoting optics
• Inductive preheating: Before pressing or welding for stress reduction and process reliability (optional)
• Joining (pressing): Force-path-monitored pressing process using a servo-mechanical unit
• Laser welding: Precise circumferential welding using proven multi-axis kinematics and seam position control sensors
• Marking: Marking of the component by laser for traceability (optional)
Each process step is seamlessly integrated into the overall system and occurs without manual intervention.
Proven laser welding technology
The laser welding station of the ELC 6i is based on the proven machine concept of the successful ELC 6, which is already used in hundreds of EMAG systems worldwide. The configuration with precisely positioned laser optics and additional axes for workpiece positioning ensures the highest precision and meets demanding tolerance requirements.
Standardization as an economic advantage
The modular and standardized design of the ELC 6i leads to measurable economic advantages for users. Investment costs are reduced by up to 15% compared to individually constructed lines, as proven standard components and predefined system configurations can be utilized. At the same time, delivery times are shortened by up to 20% because the engineering effort is significantly reduced through reusable software modules and established design solutions.
Another cost advantage arises from the simplified system architecture: A central CNC control based on Siemens Sinumerik One replaces several individual systems, significantly reducing software complexity. This positively impacts programming, commissioning, and ongoing operation. Additionally, the standardization of components improves spare parts availability and simplifies maintenance, as uniform components can be used across different systems.
The ELC 6i is conceptually designed for high utilization with quantities over 100,000 parts per year and is particularly suitable for high-volume series production, where productivity and cost control are critical success factors.
Flexibility despite standardization
Despite the consistent focus on standard processes, the ELC 6i ensures a high adaptability to different manufacturing requirements. For similar workpieces with comparable geometries and diameters, a completely conversion-free operation is possible, significantly increasing flexibility in series production.
Should conversion work be necessary, it is limited to component-specific adjustments to the workpiece fixtures, joining tools, or clamping devices and typically takes less than 20 minutes for the entire system.
Furthermore, components with special dimensions can also be project-specifically tested and integrated into the system concept. This flexible design makes the ELC 6i future-proof for product changes or platform strategies in the automotive industry, where component spectra can change over the lifecycle of a system. "The ELC 6i is the result of decades of project experience – focused on the essentials and consistently designed for efficiency, quality, and cost-effectiveness," summarizes Daniel Rujanoski the advantages of the machine.
Turnkey expertise and application development
At the in-house Laser Application Center (LAC) in Heubach, EMAG LaserTec develops individual processes together with customers, optimizes component geometries, manufactures prototypes, and supports the series launch. State-of-the-art systems for laser cleaning & structuring, welding, coating, hardening, and comprehensive testing technology are available.
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