Automotive Industry Laser Systems
Manufacturers of components for the automotive sector mark their products to identify them, to add instructions and to enable tracking and traceability. Increasingly a 2D code is required to meet the AIMDPM-1-2006 (automotive).
Lasers are used because of their ability to mark metals and a range of plastic substrates.
They are an attractive alternative to other technologies (dot pinning, scribing, etching and micro-percussion) because they are digital, clean, reliable and low cost.
Gates needed to find a more versatile solution for printing codes because all its products should be identified according security standards and to meet its customer demands. It used pads to identify and personalize the materials; printing this way needed different pads for each product and for each customer. This option was laborious, difficult and inflexible; it entailed to handle part by part by hand because of difficult positioning when marking.
Gates decided to replace its existing coding equipment and use laser marking systems. Coding rubber with a laser system is clean, ink free and provides the customer with an indelible marking and a total traceability control. Macsa systems are easy-to-program and versatile. They are ideal for short production runs.
Macsa provided a solution and installed 6 Macsa K 1010 Plus utility lasers. The marking comprises 1 line of 25 alphanumeric characters in static mode. The machines are at the final production process and during it the laser moves automatically to the middle of the belt which turns on to itself and when the laser system receives the signal from the robot, starts to code the product. When the marking is finished the laser system moves laterally to its origin point. After investigating different text formats and material locations the final marking text exceeded all quality controls from both Gates and its customers.
Gates considers MACSA laser systems as an essential part of its production line.
Application: Rubber belts
Laser system: K-1010 PLUS
About GATES P.T. SPAIN, S.A.
Gates Corporation, with headquarters in Denver, is one of the market leaders in the production of hi-tech rubber belts and hoses for industrial, hydraulic, agricultural and automotive applications. In Spain there are two subsidiary plants, both in Barcelona area, where it produces belts for the automotive sector. It is also considered the worldwide development centre of the corporation for ribbed belts.
It supplies directly to nearly all car manufacturers worldwide. It is focused on OEMs around the world that enables Gates to provide equivalent products to tier one and automotive after markets.
It is a very interesting and curious static application, due to the fact that you can only see it in exclusive cars. What they need to do with our Macsa laser is to remove the painted coating part of the plastic piece, to code a day & night graphic application (as you can see in the photograph). Then, as this piece is retro-illuminated, the light passes through the mark and then you can see this graphic shinning into the darkness.
The installation of this laser was quite simple. They mounted the L-5010 into a metal structure and in a vertical position. Then they assembled and fixed a drawer to this structure, to put the pieces to be marked in. They use a PC with our Marca software to create the night & day graphic files that will be marked onto the plastic piece (which is placed into the special drawer). It is a very simple process because they produce few pieces so they do not need dynamic laser application, due to the lack of a conveyor line.
The result of the marking process is really good, and it is so impressive because of this exclusive application. The contrast is perfect thanks to the L-5010 laser system technology. The removal of the painted coating part of the plastic piece gives a spectacular appearance to the day & night application.
Application: Light indicators
Laser system: L-5010 PLUS equivalent to D-5010 system.
This automotive firm decided to acquire a Macsa Yag 10W laser for their factory in Germany. This firm produces plastic automotive spare parts, but the ones that we mark are the light indicators of the back seats heating that you can find in Audi A6 cars.
In Spain, the Engineering and Research department of Lear Automotive (EEDS) Spain SL, needed to find a solution for codifying some of the products they produced (electrical lids, fuse lids, electronic cards, etc). These products needed to be marked permanently with variable information including: product information, serial number, traceability codes, drawings, schemes and bar codes.
Macsa proposed a system made up of a PC running with Marca software and a YAG laser marking in static mode. The YAG laser installed was a Macsa D-5005 industrial laser with 160x160 mm lenses to mark on large areas that needed a high contrast and a lot of information to be printed.
Lear is full satisfied with the solution provided by Macsa, this has been distributed to different countries, so that Macsa now operate in other production factories including: Mexico, Philippines, Spain, Germany and the current one most recently in Morocco.
“The success of Macsa is a result of its dedication to provide the best possible service, which includes understanding its customers, looking for its specific needs and the continuous improvement of its processes and product quality”.
Application: Automotive parts
Laser system: D-5005 equivalent to Nano D
Lens: 160x160 mm
About LEAR AUTOMOTIVE
Lear was founded in 1917 in Detroit as American Metal Products, a manufacturer of tubular, welded and stamped assemblies for the automotive and aircraft industries. Today, the company provides complete seat systems, electronic products and electrical distribution systems; its products are designed, engineered and manufactured by a diverse team of 71,000 employees at 210 facilities in 36 countries. Lear's headquarters are in Southfield, Michigan.
Preh Portugal, Lda had used other lasers following its head office’s policy, but recently had been looking for an alternative laser supplier who could solve all the difficulties they were currently experiencing: high maintenance costs, yag system with a short-life and, what is more significant, poor quality marking.
Macsa offered the possibility of installing a Macsa F-9010 pulsed fiber laser. With its small head it could be easily be installed within the machine developed by Preh engineers and could also be easily integrated with its current network system. The marking quality offered by the Macsa Fiber laser on a black plastic sample (white over black) and its accuracy on positioning the small customer’s logo fulfilled Preh’s expectations.
Preh’s engineering department was very familiar with laser technology and was very demanding of what Macsa laser could offer.
“We are really pleased with this solution, the Macsa F-9010 pulsed fiber laser was very easy to integrate with our production line. Our main concern, our customer’s satisfaction, has been addressed with success; the marking samples showed to it has been accepted thanks to their high-marking quality and we can trust on our supplier to solve our requirements and day-to-day issues. For these reasons, therefore, and bearing in mind all the other advantages we’ve decided to go for Macsa products and show them to our head office in Germany”
Application: Automotive parts
Laser system: F-9010 Pulsed
About Preh Group
The Preh Group is an international consortium with more than eight decades of development manufacturing experience. About 2.200 employees work on innovative technologies and individual customer solutions at locations in Germany, Portugal, France, Mexico and the United States. The Preh Group concentrates on the development and manufacturing of complex driver control systems, sensor systems, electronic control units and assembly systems for basically the automotive industry
Robert Bosch’s factory in Spain works directly for the automotive sector and needed to code its products with an indelible mark to ensure full traceability.
Macsa installed different F-1000 series CO2 lasers, networked through and controlled by Marca software.
After nine years' experience coding with F-1000 CO2 lasers, Robert Bosch decided to renovate its marking and coding systems with MACSA’s new range, K-1000 series. With a compact design and easy-to use system the Macsa K-series is the solution for marking products with incredibly clear messages at minimal operating costs.
“When we decided to upgrade our systems, we found that the new K-series would fit our needs more effectively. We found some other suppliers, some cheaper than Macsa, but we choose Macsa for customer service and obviously for the good results we have had with its previous F systems. Needless to say we are very pleased with our partner. The newer units are very fast and reliable”
Application: Automotive parts
Laser system: K-1030
About Robert Bosch
In 1886, Robert Bosch founded the "Workshop for Precision Mechanics and Electrical Engineering" in Stuttgart. This was the birth of today's globally active Robert Bosch GmbH. Now the Bosch Group employs some 280,000 people in more than 60 countries. It has a wide variety of products for different sectors as automotive, household appliances, packaging, photovoltaics systems and security systems.
Valeo’s factory in Spain produces headlights, and needs its products which different variable information. All the headlights should be marked with the following records: right or left, to which country they are going to be shipped and batch number.
Macsa decided to install a special laser secure cabin, the headlight moved automatically into the cabin, it was marked and moved back again to be removed by the operator. Depending on the message sent to the laser the system marked one or another code, giving also the starting and the final signal.
Valeo has been renewing its laser systems during the last 9 years and has also been installing new production lines marking different products and substrates. Despite having reviewed other suppliers it has always trusted Macsa and its laser systems. It has installed different laser product ranges including: Dynamark, Flymark and now the K-series. “We shopped around and determined that Macsa has the most advance systems on the market. We were concerned about security and customer service, we feel Macsa listens to us and of course, we will count on Macsa for new applications we have”.
Laser system: K-1000
The group Valeo started in 1923 in Saint Ouen, France with the production of brake linings and clutch facings. Now the Group VALEO is present in 27 countries employing more than 50.000 people. Valeo develops and offers to the market global solutions in the areas of safety, environmental protection and comfort. They are regrouped into four Business Groups: Comfort and Driving Assistance Systems, Powertrain Systems, Thermal Systems and Visibility Systems.