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Robotic Welding Technique Could Result in Lighter Cars
Project is a collaboration between Volvo Aero, SAAB Automobile and the welding equipment company ESAB.
By Robotics Trends Staff - Filed Jun 12, 2014

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Researchers at University West in Trollhättan have developed a new robotic welding technique that can reduce the weight of cars, reports Phys.org.

And it has to do with incorporating the battery into the vehicle chassis. Here's how it works, writes Phys.org:

Researchers at University West in Trollhättan have now invented a welding tool that also functions as a temperature sensor. The temperature is measured continuously and, if it becomes too hot, the heat is regulated by controlling the force and tool rotation. The researchers have also made use of an industrial robot to perform the welds and achieve a constant welding quality. Jeroen De Backer has written his thesis on this new method:

"It's thanks to this temperature controller that we've managed to raise both the quality and the productivity of the robot system. The robot welds with higher precision and with the temperature controller it only takes a few hours to programme 3D joints. Manual programming of a similar component took up to a week."

With the aid of the robot, and the temperature measurement, the researchers have also been able to weld advanced three-dimensional . This enables the welding of small and more complex components with curved surfaces. Furthermore, the energy consumption of FSW is lower than when using conventional welding methods.

The research project at University West was initiated through a collaboration between Volvo Aero, SAAB Automobile and the welding equipment company ESAB. Jeroen De Backer explains that a possible application can be hybrid and electric vehicles:

"Car manufacturers aim to reduce the weight of the electric vehicle and positioning of the heavy batteries is a key factor in this. The battery consists of different metals such as aluminium and copper. Friction stir provides the possibility to join those materials and allows thereby integration of the battery in the vehicle chassis so that the battery becomes a part of the bearing structure.



Read more at: http://phys.org/news/2014-06-lighter-cars-robotic-welding-method.html#jCp

"The researchers have also made use of an industrial robot to perform the welds and achieve a constant welding quality. Jeroen De Backer has written his thesis on this new method:

"It's thanks to this temperature controller that we've managed to raise both the quality and the productivity of the robot system. The robot welds with higher precision and with the temperature controller it only takes a few hours to programme 3D joints. Manual programming of a similar component took up to a week."

The article continues, "With the aid of the robot, and the temperature measurement, the researchers have also been able to weld advanced three-dimensional joints. This enables the welding of small and more complex components with curved surfaces. Furthermore, the energy consumption of FSW is lower than when using conventional welding methods."

"Car manufacturers aim to reduce the weight of the electric vehicle and positioning of the heavy batteries is a key factor in this. The battery consists of different metals such as aluminium and copper. Friction stir welding provides the possibility to join those materials and allows thereby integration of the battery in the vehicle chassis so that the battery becomes a part of the bearing structure.

The project is a collaboration between Volvo Aero, SAAB Automobile and the welding equipment company ESAB.

[Source]: Phys.org

Friction stir provides the possibility to join those materials and allows thereby integration of the battery in the vehicle chassis so that the battery becomes a part of the bearing structure.

Read more at: http://phys.org/news/2014-06-lighter-cars-robotic-welding-method.html#jCp
Friction stir provides the possibility to join those materials and allows thereby integration of the battery in the vehicle chassis so that the battery becomes a part of the bearing structure.

Read more at: http://phys.org/news/2014-06-lighter-cars-robotic-welding-method.html#jCp
Friction stir provides the possibility to join those materials and allows thereby integration of the battery in the vehicle chassis so that the battery becomes a part of the bearing structure.

Read more at: http://phys.org/news/2014-06-lighter-cars-robotic-welding-method.html#jCp
Friction stir provides the possibility to join those materials and allows thereby integration of the battery in the vehicle chassis so that the battery becomes a part of the bearing structure.

Read more at: http://phys.org/news/2014-06-lighter-cars-robotic-welding-method.html#jCp
Researchers at University West in Trollhättan

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