Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:

 

Every kilo shedded counts – laser welding puts the automotive industry "on a diet"

19.06.2012
Every 100 kilograms saved in vehicle weight reduces fuel consumption by up to 0.3 liters per 100 kilometers, which is why the automotive industry examines each part to determine whether it can be made even lighter.

The level of innovation behind these efforts is exemplified by passenger car transmissions, whose gear wheels and related components are manufactured by the millions and require optimized designs. To ensure that manufacturing processes run smoothly and efficiently, engineering specialist EMAG, employs high-tech solutions such as laser welding to realize spectacular results.



The differential transmission is a key component in vehicles and is manufactured millions of times over. Already perfected, is it possible to make the design even lighter? Engineers believe so and have created a simple, yet highly effective weld joint that is used by German auto makers to replace the previous threaded connection between differential components. This reduces the amount of material required, which in turn lowers the unit price of such a high-volume assembly. The weight of the differential housing is also reduced by approximately 1.2 kilograms. "This reduction is nothing short of impressive in the automotive world," explains Dr. Andreas Mootz, Managing Director of EMAG Automation.

Process integration ensures efficient production

But how is the welding work carried out? After all, enormous production quantities are involved. Automated ELC equipment from EMAG is used to manufacture the transmissions. The machine starts by loading components, then presses them together and welds the gap. Additional processes may also be carried out depending on the component handled. Each gear wheel is finished in just twelve seconds, and all differential components are fully welded in no more than 40 seconds. "Laser welding is key here and integrates technology that controls the laser beam with exacting precision," explains Mootz.

A world leader in transmission components

The welding specialists at EMAG enjoy a long history of success. Today, all renowned auto makers use laser welding in their manufacturing processes. German engineering companies also benefit from the recent market trend, which has resulted in an increased demand for gear wheels thanks in part to the dual-clutch transmission. This trend extends to conventional manual gearboxes as well, many of which integrate more gear ratios than before to further lower fuel consumption.

Contact person
Mr. Oliver Hagenlocher
Press and publishers
Tel: +49 / 7162 / 17-267
Fax: +49 / 7162 / 17-199
ohagenlocher@emag.com

Janine Christoph | EMAG Leipzig
Further information:
http://www.emag.com

More articles from Machine Engineering:

nachricht Flow probes from the 3D printer
25.05.2018 | Technische Universität München

nachricht Evaluating risk of hydrogen embrittlement: new simulation of cold cracks in high-strength steels
03.05.2018 | Fraunhofer-Institut für Werkstoffmechanik IWM

All articles from Machine Engineering >>>

The most recent press releases about innovation >>>

Die letzten 5 Focus-News des innovations-reports im Überblick:

Im Focus: Powerful IT security for the car of the future – research alliance develops new approaches

The more electronics steer, accelerate and brake cars, the more important it is to protect them against cyber-attacks. That is why 15 partners from industry and academia will work together over the next three years on new approaches to IT security in self-driving cars. The joint project goes by the name Security For Connected, Autonomous Cars (SecForCARs) and has funding of €7.2 million from the German Federal Ministry of Education and Research. Infineon is leading the project.

Vehicles already offer diverse communication interfaces and more and more automated functions, such as distance and lane-keeping assist systems. At the same...

Im Focus: Molecular switch will facilitate the development of pioneering electro-optical devices

A research team led by physicists at the Technical University of Munich (TUM) has developed molecular nanoswitches that can be toggled between two structurally different states using an applied voltage. They can serve as the basis for a pioneering class of devices that could replace silicon-based components with organic molecules.

The development of new electronic technologies drives the incessant reduction of functional component sizes. In the context of an international collaborative...

Im Focus: LZH showcases laser material processing of tomorrow at the LASYS 2018

At the LASYS 2018, from June 5th to 7th, the Laser Zentrum Hannover e.V. (LZH) will be showcasing processes for the laser material processing of tomorrow in hall 4 at stand 4E75. With blown bomb shells the LZH will present first results of a research project on civil security.

At this year's LASYS, the LZH will exhibit light-based processes such as cutting, welding, ablation and structuring as well as additive manufacturing for...

Im Focus: Self-illuminating pixels for a new display generation

There are videos on the internet that can make one marvel at technology. For example, a smartphone is casually bent around the arm or a thin-film display is rolled in all directions and with almost every diameter. From the user's point of view, this looks fantastic. From a professional point of view, however, the question arises: Is that already possible?

At Display Week 2018, scientists from the Fraunhofer Institute for Applied Polymer Research IAP will be demonstrating today’s technological possibilities and...

Im Focus: Explanation for puzzling quantum oscillations has been found

So-called quantum many-body scars allow quantum systems to stay out of equilibrium much longer, explaining experiment | Study published in Nature Physics

Recently, researchers from Harvard and MIT succeeded in trapping a record 53 atoms and individually controlling their quantum state, realizing what is called a...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

VideoLinks
Industry & Economy
Event News

In focus: Climate adapted plants

25.05.2018 | Event News

Save the date: Forum European Neuroscience – 07-11 July 2018 in Berlin, Germany

02.05.2018 | Event News

Invitation to the upcoming "Current Topics in Bioinformatics: Big Data in Genomics and Medicine"

13.04.2018 | Event News

 
Latest News

In focus: Climate adapted plants

25.05.2018 | Event News

Flow probes from the 3D printer

25.05.2018 | Machine Engineering

Less is more? Gene switch for healthy aging found

25.05.2018 | Life Sciences

VideoLinks
Science & Research
Overview of more VideoLinks >>>