With the continuous evolution of automotive manufacturing towards precision, efficiency, and lightweight, the welding quality of transmission components, as the core of power transmission, directly affects the stability, safety, and service life of the entire vehicle. DaZu Laser Intelligent Equipment Group Co., Ltd. (hereinafter referred to as "Intelligent Equipment Group"), a wholly-owned subsidiary of DaZu Laser, is deeply engaged in the field of laser intelligent manufacturing, focusing on the welding pain points of automotive transmission components. With mature welding processes and intelligent production line solutions, it provides reliable precision welding support for the industry and helps improve the quality and efficiency of automotive transmission component manufacturing.
Facing Pain Points: The Core Challenge of Welding Transmission Components
In the field of automobile manufacturing, the welding of transmission components such as clutches, differentials, transmission gears, turbochargers, and flexible flywheels generally faces the following core challenges:
High process difficulty and strict precision requirements
Welding seams are mostly circular structures, and welding deformation control and precision control of radial and end jumps are highly dependent on specialized processes and precision fixtures.
Diverse materials and strict defect control
The materials used include low-carbon alloy steel, alloy structural steel, ductile iron, etc., which impose strict requirements on welding stability and the ability to control defects such as porosity and cracks.
To withstand alternating loads, rigorous testing is required
Welds must pass stress, fatigue, and vehicle loading tests, and micro defects need to be precisely controlled.
High requirements for appearance and sealing
Need to balance sealing performance and weld aesthetics.
Accurate Empowerment: DaZu Laser High Power Welding Solution
DaZu Laser Intelligent Equipment Group's high-power laser welding technology, with its core advantages of small heat affected zone, controllable welding deformation, excellent weld depth to width ratio, and high degree of automation, accurately adapts to the full scene requirements of transmission component welding.
Clutch laser welding
The clutch adoptsCircular spot laser self welding processThe welded joint between the shell and the shaft is compatible, and the concentricity after welding can be controlled within 0.10mm. Cooperate with automatic slag cleaning, online welding seam detection, data collection and traceability, process monitoring, and remote maintenance system to effectively ensure the stability and controllability of the welding process. This process can be integrated intoClutch laser welding production lineCovering the entire process from robot feeding, laser welding, material retrieval, weld seam polishing, laser marking to material unloading, achieving full process automation and significantly reducing manual intervention.
Differential laser welding
Differential adoptsLaser wire filling welding process for ethnic groupsAdapt the radial and axial circumferential welds between the differential shell and the passive gear, and synchronously press the workpiece during the welding process to ensure the fit and stability of the welds. Compared to traditional bolted connections, this processCan eliminate bolts and corresponding processes, reduce the size and thickness of the load-bearing flange, achieve weight reduction and compact structureProvide strong support for the lightweighting of automobiles; At the same time, the welding deformation is small and the tolerance is controllable. The weld seam can bear greater torque and reduce transmission noise, greatly improving production efficiency.
To ensure the consistency and traceability of welding quality, DaZu Laser Intelligent Equipment Group has also createdDifferential welding automatic assembly lineIntegrated differential shell laser cleaning, back tooth laser cleaning, gear heating, large differential shell hot assembly, small differential shell hot pressing assembly, resistance torque detection, laser welding, weld polishing and other full process automation precision manufacturing from component pretreatment to finished product offline, greatly reducing manual intervention and ensuring that every product meets strict quality standards.
Laser welding of gears and flywheels
Welding of transmission gears
The transmission gear is composed of a ring gear and a ring gear, and adopts a large familyDeep penetration laser welding processThe equipment integrates processes such as gear cleaning, drying, pressing, preheating, laser welding, and online detection. This process can achieveWeld depth ≥ 5mm, aspect ratio ≥ 3, large weld depth to width ratio, small deformationAdding protective gas during the welding process to protect the molten pool effectively improves the welding quality. Simultaneously configure a weld quality monitoring system to monitor the welding status in real-time and ensure the stability of product welding. Through online monitoring and ultrasonic testing, precise control of defects such as welding depth and porosity is achieved. After welding, coaxiality and end face runout are strictly controlled to meet the requirements of precision transmission.
Flexible flywheel welding
For flexible flywheels, DaZu Laser Intelligent Equipment GroupAutomated Welding Production Line Solution，Fully automated assembly and processing of the flywheelEach process is automatically loaded and unloaded, effectively improving the automation level, yield rate, and production efficiency of the equipment. The welding process strictly meets the requirements: the penetration depth is ≥ 3mm, the weld seam is firm, beautiful, without cracks, and there are no pores with a diameter greater than 0.5mm. The welding deformation is small, the weld seam is formed well, the outer surface transitions smoothly, and the connection strength and appearance quality are balanced.
In addition, DaZu laser high-power welding technology can also adapt to the welding of various transmission related components such as pistons, steering columns, energy absorbing boxes, turbochargers and valves, silicone oil shock absorbers, shift forks, etc., forming a standardized and customized solution that covers the manufacturing needs of automotive transmission systems in multiple scenarios.
Intelligent Manufacturing Future: Empowering Automotive Transmission with Laser Full Scene
As a benchmark in the laser and automation popularization and application industry, Intelligent Equipment Group has been deeply involved in the field of laser intelligent manufacturing for more than ten years. It has built a vertical integration advantage from core components, complete equipment to process solutions, and accurately responds to the diverse needs of the market for customized special machines. Not only delivering high-performance equipment, but also focusing more deeply on scenario based processes to provide customers withA one-stop integrated solution from process planning, intelligent equipment to production line integration.
In the field of automotive laser welding, DaZu Laser Intelligent Equipment Group's high-power welding technology has fully covered new energy vehicle motors, batteries, as well as automotive structural components, coverings, body in white, seats, transmission components, and other parts,Forming a complete capability covering multiple scenarios of intelligent manufacturing for automobiles.
In the future, DaZu Laser Intelligent Equipment Group will continue to deeply cultivate laser precision intelligent manufacturing, promote industrial upgrading with more forward-looking technology layout and more perfect service system, and help the high-quality development of the automotive industry.
