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Sensor Manufacturing – Several Steps with a Single Laser System

Manufacturers of sensors are often in need of a simple and affordable solution for carrying out multiple processing steps in production. Because as diverse the tasks and application areas of sensors are, as manifold are their designs.

It is often necessary to joint wires on a sensor, close sheathed tubes and end faces, or expose conductors. The welding seam must always be tight and visually appealing.

ALPHA LASER offers a consistent laser-based concept for all of these tasks, with which the following processing steps can be carried out: micro welding, contact welding, tube scribing, tube cutting, sheath and end face welding.

Benefits at a glance:

  • You buy only the base machine (laser and machining table)
  • A separate table insert is available for any application, which you can purchase at a later time
  • The laser power is selected based upon your components
  • Visually appealing welding seams
Sensor Manufacturing

How Does Such a Sensor Processing Procedure Work?

First, the sensors are welded to the contacts inside the tube. This is where the “micro welding” insert is used.

The “circular welding” insert is used next, in which a specially developed holding and rotating fixture properly positions the components horizontally and vertically. Spot welding is used first for initial fixing, followed by circular welding. This process is CNC-controlled.

After filling in the insulating powder, the sheath element is hermetically sealed by welding on a pastille (end face welding).

To joint long workpieces such as wires in cables or capillary tubes, the closed laser devices VL 50 and ALS 100 feature openings with bristle grips.

These long workpieces can be inserted bundled and laser-proof into the working chamber and welded there.