Laser welding with the EMAG ELC 6i - Standardized system for powertrain components

Laser welding has become a key technology in powertrain manufacturing. Its high precision, low heat input and consistently reproducible weld seams make it the process of choice for components such as differentials, rotor shafts and intermediate shafts. At the same time, manufacturers face growing pressure to increase efficiency, save space and reduce costs.

The ELC 6i from EMAG meets these challenges with a standardized laser welding system that is compact, economical and highly reliable.

ELC 6i - Compact standard solution for industrial laser welding

The EMAG ELC 6i is a fully automated laser welding system that integrates up to six process steps in a single machine. Its standardized concept minimizes engineering effort, reduces investment costs and shortens delivery times – all without compromising on precision and process quality.

Key features at a glance:

Process integration: laser cleaning, preheating 1 (option), joining, preheating 2 (option), laser welding, marking (option)
Compact design: only approx. 21.5 m² footprint, up to 36% less space required than conventional lines
High productivity: cycle times under 20 seconds with a fixed transfer system and up to 18 workpiece carriers
Process reliability: proven multi-axis kinematics for high-precision welding processes
Cost-efficiency: up to 15% lower investment costs and up to 10% shorter delivery times.

Laser welding with the EMAG ELC 6i - standardized system for efficient series production of powertrain components — The ELC 6i: compact laser welding system for powertrain components

Integrated process sequence - laser welding in a continuous line

The ELC 6i delivers a fully integrated process chain, with each step automated and seamlessly connected within the system:

Loading and unloading - two stations for raw-part placement and two stations for removing the finished assemblies.
Laser cleaning - precise removal of impurities and coatings on the joining surfaces.
Inductive preheating 1 (optional) - reduces pressing forces and improves weld seam quality.
Joining (pressing) - force-displacement-monitored pressing process using a servomechanical unit.
Inductive preheating 2 (optional) - improves weld seam quality with challenging materials and / or component geometries
Laser welding - high-precision circumferential welding with optional wire feed and seam position control.
Marking (optional) - component marking by laser or needle marking for traceability

ELC 6i laser welding - Integrated process chain with laser cleaning, preheating, pressing, welding and marking for powertrain components — Working area of the ELC 6i: integrated stations for laser welding, laser cleaning and laser marking

Application areas of the ELC 6i

The standardized design of the ELC 6i delivers measurable economic benefits for users.

Ideal applications include:

Differentials and transmission components
Rotor and intermediate shafts
Components with circumferential weld seams

The system is especially well-suited for high-volume, price-sensitive production projects.

Laser welding with the ELC 6i - illustration of the complete process chain including laser cleaning, preheating 1, pressing, preheating 2, welding and marking of powertrain components — Process chain of the ELC 6i: from laser cleaning and pressing to laser welding and marking

Vantaggi ELC 6i

Reduced footprint: up to 36% smaller than comparable systems.
Faster delivery: up to 10 % shorter lead times with predefined modules.
Lower investment costs: up to 15 % cost savings through standardized assemblies.
High availability: simplified spare parts management and service-friendly design
Short changeover times of less than 20 minutes for component-specific adaptations.

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