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With the continuous advancement of the new energy vehicle market and the continuous improvement of its intelligence level, laser technology has also replaced many traditional processes as the trend of the times, bringing new upgrades and replacements to the entire manufacturing industry. In the welding of headlight housings, the trend of laser welding technology replacing traditional welding is becoming more and more intense.
With the continuous advancement of the new energy vehicle market and the continuous improvement of the degree of intelligence, laser technology has also replaced many traditional processes as the two points of the times, and has made new upgrades and upgrades for the entire manufacturing industry. In the welding of headlight shells, the trend of laser welding technology replacing traditional welding is becoming more and more fierce. With the continuous improvement of the requirements of automobile companies, traditional friction welding (ultrasonic welding) can no longer meet the requirements of precision taillight parts. Hot plate welding is the simplest welding process in plastic welding technology. With the development of technology, the most commonly used welding methods are vibration friction welding and ultrasonic welding. In addition, laser welding technology is also receiving more and more attention. Plastic laser welding can be seen in various welding processes. Plastic laser welding has become a potential stock for the welding process of rear headlights. It has the characteristics of beautiful welding, flexible welding and high strength. Therefore, laser welding is in line with the development trend and has become a new choice for the welding process of automobile headlights in the future.
The more common methods of laser welding are orbital laser welding, synchronous laser welding, and quasi-synchronous laser welding. Orbital laser welding is also called line welding. Welding refers to the welding in which the welding parts and the laser beam move relative to each other according to a predetermined route. As the laser beam moves, the welding material cools and solidifies after melting. The movement of the laser beam can be completed by a robot. This laser welding method reduces processing costs and reduces process damage. This plastic welding technology has a low unit cost, so it is particularly cost-effective.
Synchronous laser welding refers to the weld seam that is heated by multiple laser beams at the same time. Synchronous welding has no limit on the length of the weld seam, and the weld seam cannot be flat, which is suitable for mass production. Just distribute the pressure of the clamp evenly along the entire weld. If it is a curved surface weld of a complex curved surface, synchronous welding can complete the welding of the same plane very well. It is necessary to add a beam forming part. Evenly distribute the entire weld over the entire length of the weld.
The principle of laser welding of headlights is as follows. During the welding process, two different plastic products are clamped together under pressure. An optical path system composed of a reflector, lens or optical fiber. The beam generated by the laser is focused on the area to be welded, passes through the upper transparent material, and is then absorbed by the lower absorbing material, and the light energy is converted into heat energy, heating the lower absorbing material. And the heat is transferred to the upper transparent material. A welding area is formed on the contact surface of the two materials, and the material is melted to form a joint during the subsequent solidification process. The two materials are welded together.
The lampshade and lamp shell are made of two different materials. To achieve laser welding, the lampshade material must have a very high transmittance to the laser. And the shell material must have a very high laser absorption rate. Before welding, make sure there are no holes or convex points between the lampshade and the shell. When there are holes or convex points between the lampshade and the shell, there will be a gap between the two. And this gap cannot be removed by pressure. When the laser irradiates the shell welding steel bar surface, the heat generated by the shell welding steel bar cannot be transferred to the lampshade due to the existence of the gap, causing the shell welding steel bar to be too hot and carbonized, affecting the appearance of the entire lamp. In serious cases, it will also affect the sealing of the entire lamp.
Car headlights are also called car headlights and car LED daytime running lights. As the eyes of the car, it is not only related to the owner's external image, but also closely related to safe driving at night or in bad weather conditions. When manufacturing car headlights, they are usually composed of lamp beads, radiators, ring bases and fans. In the connection of lamp beads, radiators and bases, welding is usually used to assemble several parts of the lamp. However, car headlights often use handheld laser welding devices to fix their connectors, but the welding head part in the handheld part is easy to shake, resulting in poor connection at the welding position.
Technological advantages of laser welding of automobile headlights:
1. The beam has uniform energy distribution and stable laser output;
2. Small heat, small heat affected area, small residual stress of the workpiece, and small change;
3. Non-contact welding fiber transmission with good accessibility and high degree of automation;
4. Semiconductor laser welding can be used for high-precision plastic component welding without vibration and ultrasonic physical hazards.
5. Suitable for precision welding between metal or non-metal parts such as car lights, electronic product shielding covers, USB connectors, housings, chips, conductive patches, plastics, etc.
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