Figure 1 NewScan-3D galvanometer flight welding joint (left) NSC galvanometer control cabinet (right)
01 Technological upgrade: Collaborative breakthrough of high efficiency and high precision to build a precision welding value chain
Laser flight welding technology is a high-precision welding process based on high-speed galvanometer and dynamic focus control. Its core lies in controlling the deflection path of the laser beam through the galvanometer component, combined with real-time focal length compensation, to achieve “non-contact dynamic processing” of the beam in a fixed state of the welding head. The main advantages of this technology include high welding efficiency, fast speed, high weld strength, and small welding deformation. The NewScan-3D galvanometer flight welding system from Newlas has achieved a synergistic breakthrough in high efficiency and precision through multiple innovative technologies. It can widely cover core components of new energy vehicles (power batteries, electric drives, electronic controls) as well as high-precision welding scenarios in 3C electronics, aerospace, medical equipment, additive manufacturing, etc., providing technical support for high-quality and flexible production of complex structural components in multiple industries.
Advanced robot and linear axis flight control technology
Suitable for robot and linear axis welding stations, the real-time compensation of robot position through the controller is used to achieve control of welding position accuracy, thereby achieving safe and efficient welding operations.
Leading flight welding+OCT penetration detection technology
The combination of flight welding and OCT penetration detection technology can measure the penetration depth in real-time and accurately during the welding process, improve the overall efficiency of the production line, and accurately locate problem welding points.
Unique visual Z-axis height measurement and XY synchronous detection technology
Creatively integrating the height measurement function onto the vibrating lens, eliminating the need for separate height measurement stations and corresponding processes, is an industry first, and achieving efficient and reliable communication with the vibrating lens through a controller to complete real-time height adjustment to ensure welding quality.
Compatible with 2D/3D flight welding performance
The controller and software system are fully compatible with the flight welding operation of 2D/3D vibrating lenses, and support 3D space flight welding, achieving complete coverage of all fields and scenesCompatible with 2D/3D flight welding performance
Figure 2: Real time detection and tracking system and software interface for 3D flight welding height
Figure 3: Real time detection and tracking system and software interface for 3D flight welding in XY direction
02 Industry benchmark: High-precision welding system empowers multiple fields to boost efficient production
In specific applications, the system has performed well in multiple industries.
For example, in the field of automobile manufacturing, this system is used for welding body structural components such as doors, roofs, and chassis, improving production efficiency and product quality through high-speed and high-precision welding.
In the field of new energy batteries, this system is used for welding various types of battery modules, such as square battery busbar flight welding, cylindrical battery connecting piece flight welding, etc., to improve the processing efficiency and yield of products.
In the aerospace field, this system is used to weld key structural components of aircraft and spacecraft, such as engine parts and fuselage frames, to ensure product safety and reliability.
In the field of 3C consumer electronics, this system is capable of precision welding of small components such as sensors and connectors, ensuring the performance and reliability of electronic products.
In the field of medical device manufacturing, this system is used to produce high demand medical devices such as pacemakers and minimally invasive surgical tools, meeting strict industry standards.
In the field of additive manufacturing, 3D laser printing achieves efficient molding of complex structures through layer by layer melting and high dynamic mirror precision control, meeting the needs of high-end fields such as aerospace and medical implants.
03 Patent Foundation: Independent Core Technology Builds Global Industrial Discourse Power
The relevant technology of this system has completely independent intellectual property rights, and has obtained 7 patent authorizations so far. The specific contents are shown in the table below:
| No | Patent Name | |||
| 1 | An optical structure for laser welding | |||
| 2 | A laser processing structure and processing equipment based on a voice coil motor | |||
| 3 | An optical precision measurement method for remote laser welding of robots | |||
| 4 | A focus detection device and method for robot laser remote welding equipment | |||
| 5 | A highly synchronous tracking method and device for flying welding of power batteries | |||
| 6 | A flying welding device for two-way tracking and positioning of power batteries | |||
| 7 | A coaxial vision guidance device for galvanometer flying welding | |||
The system has been widely applied in new energy vehicle host factories and leading new energy enterprises, and its technological achievements have broken the situation of lacking safety products in the subdivision field of high-power galvanometers at the same level as foreign counterparts in China. It won the first prize of the 2024 “Mechanical Industry Science and Technology Award” for scientific and technological progress in the project “High quality and efficient laser welding technology and complete equipment for key components of new energy vehicles”.
As a high-tech company in the field of laser welding that has fully achieved full chain autonomy from “process equipment testing”, the NewScan-3D system from Newlas has built a complete technical ecosystem covering patent barriers, industry standards, and scene implementation. In the future, we will use this as a technological foundation, continue to innovate, and provide customers with more efficient, flexible, and intelligent welding solutions.
