As a green, non-contact advanced manufacturing process, laser welding has gradually become a core technology in automotive lightweight manufacturing, new energy battery module connection, and aerospace turbine blade welding, thanks to its high precision, high efficiency, and high automation. However, traditional laser welding relies on a repetitive "positioning - welding - positioning" workflow. This generates significant non-productive idle time, severely limiting actual welding efficiency and cycle time.
The emergence of laser flying welding has fundamentally changed this landscape. Unlike traditional spot welding, laser flying welding synchronously controls the robot trajectory and galvanometer scanning. This allows the equipment to "weld while moving", completing all welding tasks in continuous motion. By eliminating non-productive movement and waiting time, it makes the welding process smarter, more flexible, and highly efficient.
Unlike the industry's common reliance on external integration, Haosen is deeply committed to technological innovation. We have independently developed our 3D Laser Flying Welding System, achieving full in-house R&D in key areas such as mechanical design, electrical control, and visual positioning algorithms. The system integrates core modules including annular beam lasers, 3D galvanometers, 6-axis robots, 2D/3D vision positioning, and intelligent height measurement. Based on specific product characteristics and production scenarios, we provide customized equipment and process optimization plans, bringing a more cost-effective "Haosen Solution" to the market.
With a flying welding speed exceeding 150 mm/s and a laser output power of up to 8 kW, the Haosen 3D Laser Flying Welding System utilizes high-power annular beam welding technology. It supports circular, elliptical, sinusoidal, figure-8, and custom oscillation trajectories, along with power modulation. A single production cycle can continuously complete hundreds of weld spots, boosting overall efficiency by more than 30% compared to traditional welding methods.
Weld Seam Morphology (Left vs. Right Blowing Comparison)
Weld Cross-Section Melt Pool
The welding repeatability accuracy of the Haosen 3D Laser Flying Welding System reaches ±0.03 mm, with continuous breakthroughs being made. The 3D galvanometer features an effective Z-axis focus adjustment range of ±50 mm and an adjustment accuracy of ±0.1 mm, fully ensuring welding stability under complex working conditions.
Equipped with an OCT (Optical Coherence Tomography) online monitoring module, the system achieves full-process closed-loop control across "pre-weld, in-weld, and post-weld" stages. It detects weld spot depth in real-time with micron-level precision, dynamically adjusting laser power, defocus amount, and scanning speed to continuously calibrate weld status during the flying process. All welding data is recorded spot-by-spot for full traceability, with real-time anomaly alarms, providing strong support for quality control and process traceability.
The Haosen 3D Laser Flying Welding System boasts strong compatibility. It adapts to mainstream industrial robots like KUKA, ABB, and FANUC, as well as major laser sources and various galvanometers on the market, flexibly meeting customers' multi-brand selection and customized process requirements.
Haosen's laser flying welding equipment delivers significant advantages in productivity, quality, and reliability across various industries and applications:
In new energy battery PACK production lines, the efficiency and quality of cell connection directly impact the line cycle time. Relying on continuous, non-stop high-efficiency operations and full-process quality closed-loop control, the Haosen 3D Laser Flying Welding System achieves high-density connections for critical components like terminals and busbars, empowering production lines to improve both quality and speed.
Addressing the demands for lightweight design and high-precision assembly of core components in body-in-white manufacturing, the system efficiently completes precision welding for various structural parts, significantly enhancing body structural strength and assembly accuracy.
In the aerospace sector, high-value precision components face challenges regarding micro-deformation and high cleanliness. Equipped with OCT online monitoring, the Haosen system effectively ensures the welding reliability of complex airframe structures and new materials, such as turbine blades.
Currently, the Haosen 3D Laser Flying Welding System has successfully completed prototype validation. Looking ahead, Haosen will leverage our robust team of experts and in-house R&D capabilities to continuously deepen technological optimization, expand into more high-end manufacturing scenarios, and inject "Haosen Power" into the intelligent upgrade of the industry.
