AL-ROCK

LASER HARDENING SYSTEM WITH POWDER DEPOSIT WELDING

Mobile and Flexible Laser Hardening and Powder Deposit Welding

The AL-ROCK Is the First Mobile Robot for Targeted Hardening of Metal Surfaces.

The component to be hardened no longer needs to be dismantled, as the laser can be brought right to the workpiece. The far-reaching robot arm can easily access hard-to-reach places. All that is needed is the laser beam’s free access to the workpiece surface to be hardened.

The area which is to be hardened can be easily programmed using the scanner software: simply select the area that you wish to scan. Then the robot moves the scanner automatically to the marked area over multiple tracks. The result is a real-time 3D model. The operator then simply configures the process-relevant parameters, after which the program is simulated virtually.

The generated and confirmed program is automatically sent to the robot.

The laser beam precisely follows the workpiece contour in free 3D movements. Weld edges, nubs, grain structures, or individual points can be easily hardened this way. There is practically no thermal load on the surrounding area, which means that distortion is kept to a minimum. The heat flux within the component leads to self-quenching.

Your benefits at a glance:

  • Transporting components is not necessary (e.g., pressing tools)
  • Avoid transport damage to the component
  • Significant time savings
  • No cooling media required due to self-quenching of the workpiece
  • Low-distortion hardening due to targeted and rapid heat input
  • On-site control of the result by the customer possible
Advantages

And the AL-ROCK can do even more: The laser system can also be used for laser welding, e.g., for powder deposit welding.
Stay flexible.

  • AL-ROCK
    • Laser
      Laser type / wavelengthDiode laser, 900 – 1070 nm
      Pilot Laserred 630 – 680 nm (? 5 mW), green 532 nm (5 mW)
      Power3,000 W (CW)
      Focal distancef = 250 mm
      Shielding gas feedIncluded
      Laser cooling systemExternal water-air cooling system
      Display and operationDisplay 1 on mobile part
      Display 2 at the station with 8 mm cable for free position selection
    • Work area
      Movement speed (X, Y, Z)Welding spot 0 – 10 mm/s over component surface
      Movement range (X, Y, Z)3000 x 1000 x 1900 mm as spherical half space
      Lowest working point0 mm
      Highest working point1900 mm
      Radius of 3D work areaapprox. 2 m (from the booth)
    • Hardening
      Gaugesvariable, from 5–20 mm (depending upon the material)
      Case hardening depth (CHD)max. 2 mm (depending upon the material)
      Controlcamera-guided continuous laser output control LompocPro with E-MAqS camera
      Repeat accuracy+/- 0.08 mm max.
      Smallest programmable path dimension0.01 mm
    • External dimensions
      Mobile part W × D × H1200 x 1500 x 1800 mm
      Weightapprox. 1,400 kg
      Station including cooler W × D × H1100 x 1900 x 1800 mm
      Weightapprox. 700 kg
    • External connections
      Electrical connection63 A 400 V 3 P + PE 6 h 50 Hz
      from version P250 only 32 A 400 V 3 P + PE 6 h 50 Hz
  • Download data sheet

Ergo wedge 5°-25°

Enables tilting of the binocular for ergonomic working.

Perpendicular objective - LED ring light

The LED ring light integrated in the objective provides optimal, even, and flicker-free illumination of the workpiece in daylight quality Focusing objective f = 150 or f = 300 available and protection glass 601-0690A

Touch operating unit for 4-axis control

For adjusting the speed of the four axes of movement (semi-automatic mode) and for triggering laser pulses. The laser pulse and shielding gas are triggered simultaneously. with joystick and magnetic holder

Turn and tilt objective

Our tilting objective significantly eases work in difficult workpiece positions. In the objective's full 360° rotational range, the beam can be directed continuously up to 40° from the vertical. Moving the workpiece is not required. The beam can be conveniently directed towards difficult to access locations while maintaining an ergonomic work posture. With focusing objective f = 150, LED ring light and protection glass 

Magnetic holding sphere

for quick and easy placement of the workpiece. The slip-stick effect between the ball and the socket guarantees a secure hold of the workpiece in any position.

Halogen bulb (flexible)

Left/right pivoting beam deflection unit +/- 110 °

Flak (Nd:YAG system)

The XY and Z movement can be locked separately Available for an extra charge instead of the ball joint

Switchable micro welding function

The switchable micro welding function reduces the welding spot diameter to very fine <0.1 mm.

Rotary axis module

For welding cylindrical parts Tiltable for horizontal to vertical rotational movement. With chuck Ø 125 mm and inside diameter 24 mm

ALFT-HDMI camera system

For displaying the welding process on an external monitor The camera system is specially made for ALPHA LASER systems and is mounted below the laser's microscope attachment. Includes power supply, HDMI cable, and laser connection cable. HDMI recorder for recording not included in scope of delivery.

Laser Wire Feed System AL-DV for automated and manual laser wire deposit welding

Welding wires from 0,2 – 1,6 mm can be fed automatically

Screwable radiation protection plate

Laser Wire Feed System AL-DV for automated and manual laser wire deposit welding (only in combination with a laser work bench)

Welding wires from 0,2 – 1,6 mm can be fed automatically

Halogen dimmer

For controlling the brightness in the working chamber.

Manipulator table with ALPHA LASER quick-clamping system

for quick and safe clamping of the workpiece.

Powder deposit welding option

Consisting of welding optics, powder nozzle, powder conveyor

Turn-tilt table

with a maximum capacity of 450 kg or 1100 kg (depending on the model)

Modular mirror system

includes:

Radius hardener
(beam splitter for radii) for variable hardening track widths on bending edges

Flange hardener
(mirror for hidden surfaces) for hardening of interfering edges or hidden surfaces

Edge hardener
(beam splitter for cutting edges)

<div/>

Tube cutting table insert

Insert with rotating axis

Insert F - Circular welding with horizontal guide

This insert was specially developed for very long workpieces, i.e., for sheath and end face welding.

Left/right pivoting beam deflection unit +/- 110 °

Collet chuck

Monitor + HDMI cable

for two-dimensional representation of the welding process. The 3D laser protection goggles and monitor can be operated simultaneously.

Magnetic radiation protection plate

ALFT-HDMI camera system

For displaying the welding process on an external monitor The camera system is specially made for ALPHA LASER systems and is mounted below the laser's microscope attachment. Includes power supply, HDMI cable, and laser connection cable. HDMI recorder for recording not included in scope of delivery.

Hand rest

The leather hand rests for the working chamber offer comfortable hand positioning during welding.

50 Hz technology

Increase of max. possible pulse repetition frequency

Turn and tilt objective

Our tilting objective significantly eases work in difficult workpiece positions. In the objective's full 360° rotational range, the beam can be directed continuously up to 40° from the vertical. Moving the workpiece is not required. The beam can be conveniently directed towards difficult to access locations while maintaining an ergonomic work posture. With focusing objective f = 150, LED ring light and protection glass 

Table insert E – Sheath welding under mechanical pressure

Two parts of a sensor housing are mechanically pressed together in order to put pressure on the sealing rings while welding at the same time.

Table insert D – Laser cutting

This insert is ideal for laser cutting rotationally symmetrical parts or for removing the sheath of sheath-insulated cables. Cutting takes place in the closed working chamber.

Table insert C – Micro welding

This enables laser welding even inside the smallest thermocouples and wires. The micromanipulator enables exact positioning of the workpiece.

Table insert B – Circular welding

The integrated rotating axis rotates the sensor during the laser welding process. The circular welding table insert is used for sheath welding and end face welding for workpiece lengths of up to 1 m.

Switchable micro welding function (Nd:YAG System)

The switchable micro welding function reduces the welding spot diameter to very fine <0.1 mm.

Table insert A – Contact welding

The welded parts, e.g, sheathed lines or thermocouples - are held manually under the laser beam. 

LED ring light

Perpendicular objective - LED ring light

The LED ring light integrated in the objective provides optimal, even, and flicker-free illumination of the workpiece in daylight quality Focusing objective f = 150 or f = 300 available and protection glass 601-0690A