Case Study: Automated Laser Hardening System

Overview

We provide custom laser automation solutions that address unique manufacturing challenges, enhancing efficiency for our customers. This case study highlights our successful collaboration with RIDGID, a renowned manufacturer of hand tools and equipment, to develop an automated laser hardening system.

RIDGID sought to overcome limitations in their existing heat treating process and bring a critical operation in-house. Phoenix Laser Solutions (PLS) was chosen for our proven track record in delivering tailored automation solutions and our deep understanding of laser hardening technology.

Project

Automated laser hardening system

Application

Laser face hardening tooling

Industry

Industrial tools

Customer Challenge: Bringing Precision and Control In-House

RIDGID, a prominent player in the industrial hand tools sector, faced specific challenges related to the hardening process of critical surfaces that see heavy wear on their tools. Initially, RIDGID employed induction hardening, a method that presented limitations in achieving consistent hardness values, precise control over the hardness profile, and overall hardness uniformity across parts.

To address these shortcomings, RIDGID transitioned to outsourcing their laser hardening needs to a third-party provider, our partner Laser Hard. While this subcontracted work significantly improved the quality and consistency of their product, they became interested in bringing the process in-house to expand it to more of their product lines.

The key challenge for RIDGID was the lack of in-house ownership of the laser hardening process. While they maintained control over the entire production line from forging to the final product, this crucial hardening stage remained external. This limited their ability to respond quickly to production demands and fully integrate the hardening step within their existing processes.

Our Solution: Customized Automated Laser Hardening System

To address RIDGID’s specific needs, we engineered and built a fully automated laser hardening machine. This system utilizes advanced vision technology, a precise dial table for part indexing, and a sophisticated 6-axis robot to selectively laser harden specific profiles on RIDGID’s tool components.

The system operates with a user-friendly interface, allowing operators to select the part number. Once selected, the corresponding recipe is loaded, enabling the system to automatically locate, count, verify, and harden the parts with comprehensive feedback data provided at each stage of the process.

Collaboration was central to the success of this project. PLS worked closely with RIDGID throughout the development process, conducting regular meetings and site visits. This ensured that the final system seamlessly integrated with RIDGID’s existing facility layout, adhered to their size and space constraints, addressed all safety concerns, and aligned perfectly with their current workflow. This collaborative approach spanned all phases, from initial planning and development to the final delivery, assembly and training.

Key system components:

Comprehensive safety enclosure: Designed as a Class I laser enclosure, the system features fully light-tight and interlocked panels and entryways, guaranteeing operator safety and preventing exposure to laser radiation.
Versatile robotic arm: The integrated 6-axis robot features a wide range of motion, enabling it to access all parts within the cell and precisely articulate to selectively laser harden the required profiles on RIDGID’s components.
Precise part fixturing: Parts are securely held on a rod with servo and pneumatic actuators, ensuring accurate positioning for the robot and laser optic to effectively harden the designated part surfaces.
Integrated vision system: A vision system mounted on the robot arm inspects each part, comparing it to a reference image of the correct component. This capability allows for the automatic rejection of incorrect parts and identifies surface finish defects that could potentially impact the laser hardening process.
Advanced thermal imaging: The incorporation of a Fraunhofer EmAQS thermal imaging system is a key innovation. It provides real-time feedback and laser power modulation on the surface temperature of the area being treated. This precise temperature control is crucial for achieving consistent hardness values and case depths. This data is reinforced via cross-sectional metallurgical data from our in-house metallography lab.

Results & Benefits

The automated laser hardening system implemented by PLS has delivered significant benefits to RIDGID’s manufacturing operations for their tools, which serve a broad market of both professional and consumer users. The system uses a 3000W laser source with a zoom hardening optic, and a thermal imaging system to modulate laser power based on surface temperature.

Precise hardness control: Moving from induction hardening (which resulted in hardness variation) and outsourced laser hardening, RIDGID now benefits from precise control over hardness location, profile, and depth with lower overall heat input. They consistently achieve hardness values in the range of 54-58 HRC on parts that were previously around 38-40 HRC pre-hardened.
Significantly decreased cycle time: Operators can load the system with parts and step away to attend to the other hands-on tasks while the system processes the parts.
Improved process monitoring: The integrated thermal imaging and data logging capabilities of the system provide RIDGID with enhanced real-time quality control, allowing for immediate adjustments and ensuring consistent quality.
Reduced logistical costs: Eliminating the need to ship large quantities of parts to an external supplier has resulted in significant savings in transportation costs and reduced lead times
A safe and operator-friendly system: The Class I laser enclosure and intuitive user interface create a safer and more user-friendly working environment for operators.

The successful implementation of this laser hardening system demonstrates our expertise in developing custom automation solutions that directly address customer challenges and deliver tangible results. By bringing a critical process in-house and leveraging advanced laser technology and automation, RIDGID has gained greater control over their manufacturing process, improved product quality and consistency, reduced costs, and enhanced operational efficiency. PLS is committed to partnering with manufacturers to develop innovative solutions that drive productivity, improve quality, and ensure long-term success.