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Selective Assembly Strategy for Quality Optimization in a Laser Welding Process

: Kaufmann, Manuel; Effenberger, Ira; Huber, Marco


Weißgraeber, Philipp:
Advances in Automotive Production Technology - Theory and Application : Stuttgart Conference on Automotive Production (SCAP 2020), 9th and 10th of November 2020
Wiesbaden: Springer Vieweg, 2021 (ARENA2036)
ISBN: 978-3-662-62961-1 (Print)
ISBN: 978-3-662-62962-8 (Online)
Stuttgart Conference on the Automotive Production (SCAP) <1, 2020, Online>
Conference Paper
Fraunhofer IPA ()
Algorithmus; Geometrie; Laserstrahlschweißen; Montage; Virtuelle Produktion

Selective Assembly is used to reduce the impact of geometrical variation of parts on the quality of their assembly. Therefore, matching rules for appropriate part combinations are determined in order to optimize the assembly quality. In this work, the geometrical features which are considered for selection are derived from the Virtual Assembly of the measured individual parts. Here the measurements are performed with a Computed Tomography (CT) system. In this new approach, the complete population of parts in a batch is optimized instead of a serial optimization procedure. This minimizes or even avoids the number of waste parts. In order to apply this new assembly strategy and to evaluate the achieved results, the assembly of the cover and the housing of a screen washing nozzle is studied, which is joined by laser welding. By means of global optimization using a genetic algorithm, the overlap in the welding seam, which determines the quality of the final product, is optimized. Deviations to the nominal welding seam are reduced up to 45% compared to a worst case assembly.