EQUIPMENT · GERMANY
EMAG LaserTec Laser Welding and Cleaning Systems
We supply turnkey EMAG LaserTec systems for laser welding, cleaning and cladding, built in Heubach, Germany: the ELC 6, ELC 6i, ELC 160, ELC 600, ELC 1200 V, ELC LMD and LC 4-2 series.
We match the system to your part: a differential housing, a gear with a synchronizer body, a rotor shaft or a brake disc.
ELC 6i: standardized system for circumferential welds
A new standardized system for differentials, rotor shafts and intermediate shafts. Up to six steps in one line: cleaning, preheating, joining, welding and marking.
- Workpiece up to 300 mm diameter, 300 mm high
- Axial weld diameter 75/200 mm, radial 75/250 mm
- Cycle time under 20 seconds, footprint 21.4 m²
- Siemens Sinumerik One control
ELC 6: rotary indexing production system
The series flagship for classic powertrain parts with circular welds. The machining station is separate from the loading station, the lens is fixed and the workpiece moves.
- Workpiece up to 300 mm diameter, 300 mm high
- Axial weld diameter 75/200 mm, radial 75/250 mm
- Joining force up to 10 kN, 30 kN optional
- Mainly electric drives instead of hydraulics and pneumatics
ELC 160: gears and synchronizer bodies
A modular system that press-fits the synchronizer body onto the gearwheel and welds the two parts with a laser beam. Three NC axes and stationary process modules.
- Single, DUO and TRIO versions
- CO2 and fiber-guided lasers (fiber, disc)
- Force and displacement monitoring of pressing
- Gear shafts and rotor shafts
ELC 600: large truck components
A system for the commercial vehicle industry. The typical part is a truck differential housing weighing up to 130 kg, made of cast or case-hardened steel.
- Workpiece up to 600 mm diameter and 600 mm high
- Clamping force up to 100 kN, up to 3 fixtures
- Solid-state laser up to 8 kW
- Siemens Sinumerik 840D sl, torque test up to 65 Nm
ELC 1200 V: vertical system for shafts
Welding, laser cleaning and laser hardening of shafts. Loading and unloading run in parallel with machining on a rotary indexing table; manual or fully automatic operation.
- Diameter up to 300 mm, length 50–1200 mm
- Workpiece weight up to 10 kg
- Cycle time from 6 seconds, footprint 4.3 m²
- Lens axes X, Z, B and C-axis
ELC LMD: laser cladding of coatings
Modular systems apply a wear-resistant layer by laser metal deposition of powder. The main use is brake discs; hydraulic rods, rollers and wind turbine plain bearings are also covered.
- Mono, Duo and Trio versions
- Powder feed up to 150 g/min
- Melt pool monitoring camera
- Material change in under 30 seconds
LC 4-2: laser cleaning of parts
A stand-alone machine removes oxides, dirt particles and polymer lubricant residues without cleaning agents. It prepares surfaces for welding or coating.
- Workpiece up to 200 mm diameter, 350 mm high
- 200 W fiber laser
- Footprint 1500 × 3050 mm
- Siemens Sinumerik 840D sl control
Which system for which part
A starting point for the first discussion: choose the part, and we refine the rest from the drawing and annual volume.
- Differential housing: ELC 6, ELC 6i, ELC 600 for trucks
- Gear and synchronizer: ELC 160
- Shaft up to 1200 mm long: ELC 1200 V
- Brake disc: ELC LMD and LC 4-2
ELC 6i process chain
The system combines up to six steps: part loading, laser cleaning, optional preheating, servo-mechanical joining, laser welding and optional marking. Preheating reduces the pressing force.
According to the manufacturer, with a cycle under 20 seconds the system carries 14 to 18 workpiece holders, changeover to another part takes about 20 minutes, and the standard configuration pays off from roughly 100000 parts per year.
Where ELC systems are used
The manufacturer names gear wheels, differentials and clutch components, steering parts, and preheating and joining systems for camshafts and transmission shafts.
New fields are electric motor rotor shafts and large truck parts above 100 kg. Laser welding joins cast materials with case-hardening steels, giving lighter parts than forged ones with little distortion.
The manufacturer states that ELC systems have been delivered to major automotive manufacturers; for selection the part, material, weld and output volume matter most.
The Heubach plant
EMAG LaserTec is the successor of Heilig Automation. It has belonged to the EMAG Group since March 2001 and has carried the EMAG LaserTec name since January 2019.
By 2019 it had developed and delivered more than 160 customized laser welding systems. Its solutions cover machining, laser welding, thermal joining and ultrasonic inspection.
What laser welding delivers
The manufacturer calls laser welding a precondition for compact, weight-optimized components and energy-efficient vehicles. Beam intensity is adjustable, welding speed is high and distortion is minimal.
Modern laser sources and optimized workholding reduce post-weld finishing. The process is used in powertrain, chassis and gearbox parts where new part geometries are needed.
System designations
ELC stands for EMAG Laser Cell. The welding systems are the ELC 6, ELC 6i, ELC 160, ELC 600 and the vertical ELC 1200 V; the ELC 160 comes in Single, DUO and TRIO versions.
The ELC LMD cladding systems come in Mono, Duo and Trio versions, and cleaning is the LC 4-2. The version defines throughput and the number of independent stations.
Turnkey project approach
The manufacturer stresses that process development is an important decision factor: EMAG LaserTec takes responsibility for the whole technology, from machining to laser welding, thermal joining and ultrasonic weld inspection.
For us this means that questions about the part, material and cycle time are solved with one maker rather than with several component suppliers.
Economics of the standard ELC 6i
The standard system needs 21.4 m², 36% less than a conventional line. The manufacturer states up to 15% lower investment costs and up to 10% shorter delivery times.
The economic threshold is about 100000 parts per year. For smaller series compare the ELC 6i with the ELC 6 and ELC 160.
Cleaning and cladding in one chain
The LC 4-2 evaporates contamination with a laser beam, with direct extraction and filtration, uses less energy than a washing unit and is practically maintenance-free.
The ELC LMD then applies the wear-resistant layer: a camera watches the melt pool, a scanner measures coating thickness, friction roller conveyors move the parts, and positioning takes 0.8 seconds.
Safety and the fixed-lens principle
In ELC systems the lens is fixed and the workpiece moves. According to the manufacturer this gives maximum operating safety: the beam works inside the station. Loading and unloading run separately from machining, which cuts idle time.
Drives are mainly electric rather than pneumatic or hydraulic, and the lasers are high-efficiency: the manufacturer links this to lower operating costs.
Laser sources
The ELC 160 works with CO2 lasers and fiber-guided systems (fibers, discs). The ELC 600 is fitted with a solid-state laser up to 8 kW and is compatible with Precitec welding optics and sensors.
The LC 4-2 uses a 200 W fiber laser. The source type is chosen for the part and the required weld.
Controls and monitoring
The ELC 6i runs on Siemens Sinumerik One; the ELC 600, ELC 1200 V and LC 4-2 use Sinumerik 840D sl. The ELC 160 monitors pressing force and travel, and the ELC 600 has a 65 Nm torque test system.
The ELC 1200 V has the EDNA interface with Teach-in and a connection to data collection systems.
Materials and joints
The ELC 600 welds cast and case-hardened steel at great depth. The ELC 160 can heat parts magnetically for demanding materials, and the ELC 6i offers preheating to reduce the pressing force.
The tooling is designed for minimal distortion, so post-weld finishing is reduced.
Vertical layout of the ELC 1200 V
The vertical system needs 4.3 m² of floor space. The lens moves on X, Z and B axes, the clamping device has a C-axis, and control is Siemens Sinumerik 840D sl with the EDNA interface.
A new part is set up by Teach-in, and the system connects to data collection systems. Loading and unloading run in parallel with machining.
What we need for a quotation
Send the drawing or part description, the material (for example cast or case-hardened steel), diameter and height, axial and radial weld diameters, annual volume and target cycle time.
Add the preferred laser type, whether the system must join a line, and the Siemens control version used at your plant. With this data we agree the system version with the manufacturer.
How we work
We take your drawing or part description, material, annual volume and required cycle time. We agree the system version, laser type and tooling with the manufacturer.
We arrange supply, delivery and documentation. Spare parts for the systems are selected by model and serial number.
For a new project we request a technical and commercial offer from the manufacturer and confirm the production time and scope of documentation. We work in Russian, English and Chinese, and accept drawings and specifications as PDF, STEP or DXF.
Documents and sources
Price, lead time and scope are set at quotation for your project. Technical data follows the manufacturer official materials and may differ in a specific version. Trademarks belong to their owners.
