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Assembly of a stationary robot-based laser system for laser hardening, cladding and additive manufacturing

Precise and powerful

ALOstation

ALOstation

Stationary laser systems

We offer our customers state-of-the-art system integration for the optimum processing of components, characterised by high performance and flexibility.

Straightforward and efficient

The ALOstation concept

The ALOstation is a stationary robot system for the precise surface processing of components. It combines the technologies of laser hardening, laser cladding with powder or wire as well as arc welding (CMT welding). It is based on a high-quality industrial robot with 6 synchronised axes, which can be expanded to up to 16 synchronised axes using modular components such as a linear unit or turn/tilt table. The surfaces are processed using high-precision processing heads and a fibre-coupled high-performance diode laser with an output power of up to 45 kW. The technology can be changed swiftly and easily thanks to our quickcoupler system.

Operation of the ALOstation is simple and straightforward thanks to predefined macros (programming assistant) and laser power control using the E-MAqS thermal imaging camera and LompocPro control system.

ALOstation – we build your system according to your needs!

ALOstation laser system

Versatile use

In addition to the possible applications for surface hardening, repair and cladding as well as welding and additive manufacturing, the ALOstation impresses with a fast and smooth technology change using a quickcouple system, up to 16 synchronised axes and user-friendly operation and control.

Laser hardening Arc welding

Stationary laser system for hardening
Stationary laser system for cladding with powder

Laser cladding with powder and wire

Stationary laser system for cladding with wire
Stationary laser system for cladding with powder

Quick and easy technology change

Stationary laser system for laser hardening and cladding
Stationary laser system for laser hardening and cladding

Technology in stationary operation

Wide range of applications

Laser hardening ALOhard with fixed and variable laser track width and dynamic scanning optics, laser powder cladding ALOpowder with fixed and variable laser track width as well as internal cladding, laser wire cladding ALOwire and CMT welding ALOarc in mould and tool making and mechanical engineering

Specific hardening of metallic surfaces and repair or reconditioning of highly stressed component surfaces, cladding and additive manufacturing

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 the wear behaviour
  • Use with fixed, variable laser track width and dynamic laser beam guidance

Laser cladding

with powder

  • Application of wear protection on components
  • Repair of worn components
  • Rapid modification of component geometries
  • Use with fixed and variable laser track widths and with internal cladding optics
  • Additive manufacturing

Laser cladding

with wire

  • Applying wear protection to components
  • Repair of worn components
  • Rapid modification of component geometries
  • Additive manufacturing

Arc welding

CMT welding with ALOarc

  • Especially suitable for high deposition rates
  • For cladding and joint welding
  • Additive manufacturing
Additive manufacturing with CMT welding

System engineering

Around the world

  • System for laser hardening

    Robot system for laser hardening with turn/tilt table and tilting table.

    Switzerland · Egerkingen
    Härterei Gerster AG

  • System for laser hardening

    Setting up the robot system for laser hardening.

    Switzerland · Egerkingen
    Härterei Gerster AG

  • System for laser hardening

    Setting up the robot system for laser hardening.

    Switzerland · Egerkingen
    Härterei Gerster AG

  • System for laser hardening

    Handover of the robot system for laser hardening to Härterei Gerster AG in Egerkingen, Switzerland.

    Switzerland · Egerkingen
    Härterei Gerster AG

  • System for laser hardening

    Robot system for laser hardening with 2 turn-tilt axes in separate laser chambers for increased efficiency and profitability.

    Austria

  • System for laser hardening

    Robot system for laser hardening with 2 turn-tilt axes in separate laser chambers for increased efficiency and profitability.

    Austria

  • System for laser hardening

    Robot system for laser hardening with 2 turn-tilt axes in separate laser chambers for increased efficiency and profitability.

    Austria

  • System for laser cladding

    Robot system for laser cladding with powder for external and internal coating, including rotary tilting table with 2 axes for part positioning.

    Belgium · Waregem
    Gearcraft Vanhoutte

  • System for laser cladding

    Robot system for laser cladding with powder for external and internal coating, including rotary tilting table with 2 axes for part positioning.

    Belgium · Waregem
    Gearcraft Vanhoutte

Stationary laser processing

Advantages of the ALOstation

Scalable laser systems and modules

Scalable systems and modules

Customised design – according to your requirements

Stationary laser systems with up to 16 synchronized axes

Up to 16 synchronised axes

when used on a linear unit and turn/tilt table

Fast technology changeover with the ALOtec quickcouple system

Fast technology changeover

with the ALOtec quickcouple system

Continuous documentation of process parameters and laser power

Continuous documentation

of process parameters and laser power

State-of-the-art technology thanks to in-house research and contract manufacturing

State-of-the-art technology

thanks to in-house research and contract manufacturing

Maximum laser power up to 45 kW laser power possible

Maximum laser power

Up to 45 kW laser power possible

Simple system operation straightforward operation thanks to predefined programme sequences

Simple system operation

Straightforward operation thanks to predefined programme sequences

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

Offline programming

via CAD/CAM and geometry scan for path planning

Reliable service and support worldwide maintenance, system updates and training

Reliable service and support

Worldwide maintenance, system updates and training

Robot of a laser system

Modular system

Technical equipment

We design and manufacture your customised, stationary laser system for hardening, cladding with powder and wire or for 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
  • Different reach depending on the system configuration
  • Different payload depending on system configuration

Laser

Power

  • Fibre-coupled high-power diode laser (other lasers possible)
  • Laser power: up to 45 kW

Optics

Hardening / Cladding / CMT welding

  • Laser hardening ALOhard (fixed laser track width), ALOhardzoom (variable laser track width), ALOhardscan (dynamic laser optics)
  • Powder deposition welding ALOpowder (fixed laser track width), ALOpowderzoom (variable laser track width), ALOpowderID (internal coating optics), ALOpowderwide (wide jet nozzle)
  • ALOwire wire cladding
  • Powder and wire cladding ALOtwin as a hybrid technology
  • 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 tanks
  • Turning table
  • Many other peripheral devices depending on configuration

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

Control station for stationary systems

Control station for stationary systems

Turn/tilt table with 1 and 2 axes for positioning

Turn/tilt table with 1 and 2 axes for positioning

Rotary table with 1 axis for positioning

Rotary table with 1 axis for positioning

Rotary module with variable steady rest

Rotary module with variable steady rest

Modules and accessories such as powder feeder

Modules and accessories such as powder feeder

Modules and accessories such as wire feeder

Modules and accessories such as wire feeder

Laser module with up to 45 kW laser power

Laser module with up to 45 kW laser power

Exhaust and cabin exhaust

Exhaust and cabin exhaust

Laser protection concept with customised safety cabins

Laser protection concept with customised safety cabins

Looking for a stationary system with straightforward operation?

Let’s talk.

The ALOstation laser system is designed for a wide range of applications and is modularly expandable. Operation is simple and pre-installed programme sequences guide you quickly and safely through the processes.

Stationary laser system repairs a bearing seat with cladding

Our laser systems in the moving picture

Roll it – Laser on

ALOflex – Robot system for mobile laser processing