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Hybrid laser system for repairing a bearing seat with laser powder cladding

Precise and mobile

ALOhybrid

ALOhybrid

Hybrid laser systems

ALOhybrid is the world’s first hybrid 10-axis system for laser processing – a perfect combination of a stationary and mobile laser system.

Precision and mobility

The ALOhybrid concept

With the ALOhybrid laser system, you get the precision of a stationary system and the flexibility of a mobile laser processing system. The system is suitable for processing forming tools, machine parts, cutting tools or screw conveyors, rollers and shafts and much more.

In mobile use, the robot is connected to the media station via a 15 metre long, flexible energy chain and has a large, mobile working radius.

The ALOhybrid is designed for alternating use as a stationary system on a linear unit and as a mobile system on a crawler or directly on the component to be machined using a multi-clamping plate.

ALOhybrid – mobile and stationary use!

Hybrid laser system ALOhybrid

Flexible and precise

As well as being suitable for use as a stationary or mobile system, the ALOhybrid impresses with a fast and smooth technology change using a quickcoupling system, 10 synchronised axes and user-friendly operation and control.

Mobile use Laser hardening with zoom

Mobile laser hardening with zoom optics
Mobile laser hardening with zoom optics

Stationary use Laser cladding

Use on a linear unit as a stationary laser system
Use on a linear unit as a stationary laser system

Technology change with quickcoupling system

Technology change with quickcoupling system
Technology change with quickcoupling system

Technology in hybrid operation

Wide range of applications

ALOhard and ALOhardzoom laser hardening, ALOpowder laser powder cladding and ALOarc CMT welding in mould and tool making and mechanical engineering

Specific hardening of metallic surfaces and repair or reconditioning of highly stressed component surfaces

Suitable for processing forming tools, machine parts, cutting tools or screw conveyors, bearing seats, rollers and much more

Laser hardening

with fixed and variable laser track widths

  • For maximum hardness values on the component surface
  • Improvement of wear behavior

Arc welding

CMT welding with ALOarc

  • Specially suited for high deposition rates
  • For coating and joint welding
  • Additive manufacturing

Cladding

with powder

  • Application of wear-resistant coatings on components
  • Rapid modification of component geometries

Additional applications can be optionally employed: laser powder cladding with interior cladding optics* ALOpowderID, laser wire cladding* ALOwire, hardening with dynamic scanning optics* ALOhardscan, and a hybrid technology combining wire and powder cladding* ALOtwin.

*For these applications, modules of the hybrid laser system need to be adjusted.

On site at the customer component

Mobile processing

  • Transporting the mobile laser system

    The components of the laser system are compactly stowed away for easy transportation.

  • Loading the mobile laser system

    The components of the laser system are located in transport-optimized stations and are therefore quick to load and easy to transport.

  • Setting up the mobile laser system

    The mobile laser system is positioned and set up on site on the component.

  • Teaching the mobile laser system

    Simple creation of the welding paths on the component by teaching the mobile laser system.

  • Setting up the laser safety barriers

    Setting up the certified laser safety barriers around the component with the mobile laser system.

  • Setting up process control

    Setting up system monitoring and process control, laser power measurement and documentation of process parameters using OPC UA.

  • Fully set up mobile laser system

    The system and the powder feeder are positioned in front of the component and fully set up.

  • Process recording

    Recording of the process camera during laser powder cladding on the component.

  • Finished bearing seat

    Welding pattern as a meander track on a bearing seat with a track width of 3.8 and a layer height of 1.0 mm

  • Use as a stationary system

    After the mobile repair work on site on the component, the laser system continues to be operated as a stationary 10-axis laser system.

Hybrid laser processing

Advantages of ALOhybrid

Use on crawler tracks, on components or as a stationary support

Precision and flexibility

Use on crawler tracks, on components or as a stationary support

Up to 8 for mobile use and up to 10 synchronised axes for stationary use

Up to 10 synchronised axes

Up to 8 for mobile use and up to 10 synchronised axes for stationary use

Fast technology changeover with the ALOtec quick-change system

Fast technology changeover

with the ALOtec quick-change system

Continuous documentation of process parameters and laser power

Continuous documentation

of process parameters and laser power

Simple system positioning on the component with the help of the crawler

Simple system positioning

on the component with the help of the crawler

Up to 10 kW laser power possible

Maximum 10 kW laser power

Up to 10 kW laser power possible

Simple operation thanks to predefined programme sequences

Simple system operation

Simple operation thanks to predefined programme sequences

Offline programming via CAD/CAM and scan of the geometry for path planning

Offline programming

via CAD/CAM and scan of the geometry for path planning

Optimised transport dimensions for trucks, ships or planes

Sophisticated transport concept

Optimised transport dimensions for trucks, ships or planes

Hybrid laser system with optics for laser powder cladding

Modular system

Technical equipment

We design and manufacture your customised, mobile and stationary laser system for hardening, cladding with powder and wire or CMT welding.

Connections

Electricity / Compressed air / Gas

  • Power supply: 400 V / 50 Hz / 32 A (depending on system configuration)
  • Compressed air: 6 bar
  • Gas: Argon 7 bar

Robot

Axes / Reach / Payload

  • 6-axis robot
  • Reach: from 1.81 m
  • Payload: from 20 kg

Laser

Power

  • Fibre-coupled high-power diode laser
  • Laser power: up to 10 kW

Optics

Hardening / Cladding / CMT welding

  • Hardening ALOhardzoom: Zoom optics 5 mm – 40 mm (2D zoom optics)
  • ALOpowder cladding: Variable spot size
  • CMT welding ALOarc

Peripherals

Positioner and linear unit

  • Linear unit
  • Turn/tilt table with 2 axes for positioning
  • Rotary table with 1 axis for positioning
  • Rotary module for shafts and containers
  • Turning table

Add ‑ on

Auxiliary and additional devices

  • Laser power control
  • Line scanner
  • 3D probe
  • Modular mirror system suitable for ALOhardzoom
  • Clamping device

Software

Auxiliary and additional devices

  • Software for laser power control
  • Offline programming software
  • Macros (programming assistant) for easy operation
  • Scanning software for 3D surface digitisation

Customised equipment

System modules

Processing optics for laser hardening and cladding

Processing optics for laser hardening and cladding

6-axis robot for 3D laser beam movement

6-axis robot for 3D laser beam movement

Linear unit for stationary use

Linear unit for stationary use

Crawler unit with remote control for mobile use

Crawler unit with remote control for mobile use

Turn/tilt table with 1 or 2 axes for positioning

Turn/tilt table with 1 or 2 axes for positioning

Mobile media station for mobile systems

Mobile media station for mobile systems

Mobile station for safety barriers and robot

Mobile station for safety barriers and robot

Laser safety barriers with certified laser protection concept

Laser safety barriers with certified laser protection concept

Want the best of both worlds?

Here it is:

The ALOhybrid hybrid laser system is designed for a wide range of applications and is modularly expandable. It is easy to operate and pre-installed programme sequences guide you quickly and safely through the processes.

Hybrid laser system for cladding with powder

Our laser systems in the moving picture

Roll it – laser on

Mobile laser hardening of pressure sleeves
ALOflex – Robot system for mobile laser processing