PI 069-13 Lohr am Main, 2013-07-12

Combining steel and aluminum in a reliable and cost-effective manner

Due to a series production-ready system solution from Rexroth, automotive manufacturers can weld aluminum in auto body construction in a reliable manner and at the cost level of steel for the first ti

Rexroth is a system partner for aluminum welding in auto body construction

Automotive manufacturers increasingly rely on lightweight constructions in order to reduce the weight and therefore the consumption. This trend changes their approach to auto body construction. More and more often, automotive manufacturers use aluminum as material and therefore have to develop competencies in the area of aluminum welding. Bosch Rexroth is the only supplier worldwide that fulfills cost-effectiveness and process safety requirements also with regard to aluminum welding. Due to a series production-ready system solution from Rexroth, automotive manufacturers can weld aluminum in auto body construction in a reliable manner and at the cost level of steel for the first time.

The methods for fastening aluminum used so far, such as riveting, are significantly more expensive than resistance spot welding. Not only does the adaptive welding inverter for aluminum developed by Rexroth take into account the physical particularities of the material but it also enables the complete monitoring and control of the welding procedure during the process. This increases the cost-effectiveness, since, until now, the manufacturers had to check the welds for quality control purposes after the processing in a separate process step.

Rexroth supports the fast commissioning of welding equipment through the new software function STC Teach (Sheet Thickness Combination). With this function, automotive manufacturers can optimize the welding processes irrespective of the material for different sheet thickness combinations in the laboratory in advance. The parameters are fed into a database, where the manufacturer stores all the welding combinations used. Thus, when new welding stations are commissioned or when the series production of new models is launched, all plants of the manufacturer around the globe have access to these parameters. Simply copying the respective sets of data to the welding control is all that is required to launch the series production immediately afterwards.

Furthermore, automotive manufacturers can save precious space and cable length, both of which have been required so far by welding stations distributed over different places in the auto body construction. The new welding control cabinet from Rexroth combines welding and servo gun control in one compact control cabinet concept. Since they comply with protection class IP 54, the control cabinets can now be placed significantly closer to the production process than before. Rexroth offers different versions for the realization as suspended installation, free-standing or robot control cabinet.

Bosch Rexroth has been a system partner of automotive manufacturers for more than 60 years and offers the whole range of cost-effective and reliable welding solutions - also for aluminum.

Rexroth completes the range of customer-specific welding solutions with an extensive line of transformers, which includes, for example, the standardized platform transformer for use in the automotive industry. It is compatible with virtually all robot applications. The monitoring function between the inverter and the transformer as well as the compact design and the light weight ensure maximum cost effectiveness and precision.

Economical, precise, safe, and energy efficient: drive and control technology from Bosch Rexroth moves machines and systems of any size. The company bundles global application experience in the market segments of Mobile Applications, Machinery Applications and Engineering, Factory Automation, and Renewable Energies to develop innovative components as well as tailored system solutions and services. Bosch Rexroth offers its customers hydraulics, electric drives and controls, pneumatics, gear technology, and linear motion and assembly technology all from one source. With locations in over 80 countries, more than 37,500 associates generated sales revenue of approximately 6.5 billion euros in 2012.

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The Bosch Group is a leading global supplier of technology and services. In fiscal 2012, its roughly 306,000 associates generated sales of 52.5 billion euros. Since the beginning of 2013, its operations have been divided into four business sectors: Automotive Technology, Industrial Technology, Consumer Goods, and Energy and Building Technology. The Bosch Group comprises Robert Bosch GmbH and its roughly 360 subsidiaries and regional companies in some 50 countries. If its sales and service partners are included, then Bosch is represented in roughly 150 countries. This worldwide development, manufacturing, and sales network is the foundation for further growth. Bosch spent some 4.8 billion euros for research and development in 2012, and applied for nearly 4,800 patents worldwide. The Bosch Group’s products and services are designed to fascinate, and to improve the quality of life by providing solutions which are both innovative and beneficial. In this way, the company offers technology worldwide that is “Invented for life.”

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Susanne Herzlieb
Maria-Theresien-Straße 23
97816 Lohr am Main
Phone: +49 9352 18-1573