EMAG ELC 6i - Standardized laser welding system for powertrain components

Standardized complete solution for automated process chains

The ELC 6i is based on EMAG’s extensive experience from numerous laser welding projects. The goal was to create a repeatable system concept that maps all the key steps - from cleaning and joining to welding and marking - in a single machine. By focusing on essential functions and eliminating unnecessary options, the ELC 6i delivers exactly what most applications require.

Daniel Rujanoski, Director Global Sales & Applications at EMAG LaserTec, explains:
"With the ELC 6i, we offer a laser welding system that provides high customer benefits with reduced engineering costs through standardization. Unit costs and delivery times can be significantly reduced, especially for large quantities with recurring requirements."

Compact design - up to 36% less space required

The space requirement of industrial production lines is a critical economic factor. The ELC 6i combines up to six stations in an area of just approx. 21.5 m². Compared to conventional, individually designed line concepts, this results in a space saving of more than 30 %. This compactness is achieved through consistent layout planning with a central rotary indexing conveyor, integrated laser safety housing and standardized handling modules.

The transfer system, equipped with up to 18 workpiece carriers, moves the components through all stations in a fixed cycle. Two components advance per cycle, enabling parallel processes and very short cycle times of less than 20 seconds.

Integrated process sequence for maximum efficiency

The ELC 6i maps a complete process chain within a single system:

• Loading and unloading: Two stations each for loading and unloading the workpieces
• Laser cleaning: "Selective" cleaning of both component partners using a laser, guided by oscillating optics
• Inductive preheating: Before pressing or welding for stress reduction and process reliability (optional)
• Joining (pressing): Force-displacement monitored pressing process using a servomechanical unit
• Laser welding: Precise circumferential welding using proven multi-axis kinematics and seam position control sensors
• Marking: Laser marking of the component for traceability (optional)

Each process step is seamlessly integrated into the overall system and takes place without manual intervention.

Proven laser welding technology

The laser welding station of the ELC 6i is based on the proven machine concept of the successful ELC 6, already in use in hundreds of EMAG systems worldwide. The configuration with precisely positioned laser optics and additional axes for workpiece positioning ensures maximum precision and meets even the most demanding tolerance requirements.

Standardization as an economic advantage

The modular and standardized design of the ELC 6i leads to measurable economic benefits for users. Investment costs are reduced by up to 15% compared to individually designed lines, thanks to proven standard components and predefined system configurations. Delivery times are also shortened by up to 20%, as the engineering effort is minimzed through reusable software modules and established design solutions.

The simplified system architecture provides a further cost advantage: a central CNC control system based on Siemens Sinumerik One replaces several individual systems, significantly reducing software complexity. This improves programming, commissioning and ongoing operation. Additionally, standardized assemblies enhance spare parts availability and simplify maintenance, as uniform components are used across different systems.

The ELC 6i is designed for high capacity utilization with quantities of over 100,000 parts per year and is particularly suitable for high-volume series production, where productivity and cost control are critical success factors. 

Flexibility despite standardization

Although the ELC 6i is designed around standardized processes, it offers a high degree of adaptability to different production requirements. For similar workpieces with comparable geometries and diameters, completely changeover-free operation is possible, which significantly increases flexibility in series production. If changeover work is required, this is limited to component-specific adjustments to the workpiece holders, joining tools or clamping devices and usually takes less than 20 minutes for the entire system.

Additionally, components with special dimensions can be tested on a project-specific basis and integrated into the system concept. This flexible design makes the ELC 6i future-proof for product changes or platform strategies in the automotive industry, where component spectra can change over the life cycle of a system. "The ELC 6i is the result of decades of project experience - focused on the essentials and consistently designed for efficiency, quality and cost-effectiveness," says Daniel Rujanoski, summarizing the advantages of the machine.

Turnkey expertise and application development

At the in-house Laser Application Center (LAC) in Heubach, EMAG LaserTec develops individual processes together with customers, optimizes component geometries, manufactures prototypes and supports the start of series production. State-of-the-art systems for laser cleaning & structuring, welding, coating, hardening and comprehensive testing technology are available.

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