Remote welding system


Laser power up to 8 kW // Suitable for integrating CO2 lasers and fiber lasers // Highly dynamic drive unit


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FLACS RWS - remote welding system

Laser power up to 8 kW

The FLACS.RWS remote welding system is
the ideal basis for welding metal components.
Laser power of up to 8 kW can be used. The
system is suitable for integrating CO2 lasers
and fiber lasers.

System versions

The components can be fed in through various versions:

  • Stationary table
  • 2-station turn table
  • Multi-station turn table
  • Industrial robot
  • Transport system



The RWS remote welding box is based on a completely new functional
structure with highly dynamic linear motors and direct drives for
diverting the mirror axis. The system is controlled via IRC 5, a world-
renowned ABB robotic control system.

This allows for very simple and functional programming. In addition, it
can be programmed right at the component manufacturer’s work-
place using RobotStudio, an offline programming system. This avoids
system downtimes, in turn providing enormous savings potential.


The two integrated linear axes consist of two water-cooled, highly
dynamic linear motors that can follow both the Z axis shift and
the working positions of the scanner mirror. Each axis is equipped
with a brake.


The bending mirror is designed in such a way that no warping
occurs during assembly, which means there is no disad-
vantage for the focus point. The mirror is controlled via two
direct drives, with a water-cooled design. This makes
them highly dynamic. Each axis is equipped with a brake.


The RWS FLEX is controlled via the standard ABB robotic controls. The major
advantage here lies in the simple programming, the universal imple-
mentation and the simple communication with peripheral modules. Prior
experience with ABB programming can thus be applied directly.


The compact structure of the rotary drive for the mirrors allowed
us to make the exit window significantly smaller. This provides
better dust protection for the entire system. The beam exit window,
moving in sync with the mirror carriage, can be freely posi-
tioned anywhere within the work area. The remaining path is pro-
tected by metal slats against sparks and reflections from below.


The beam expansion system is completely integrated into
the remote box and encapsulated. It is programmed using familiar


Lasers can be either CO2 lasers,
manufactured by Rofin Sinar,
or fiber lasers. The typical laser
power is between 4 - 8 kW.


Beam guidance takes place through a completely
closed system with three bending mirrors.
The entire beam path is flooded with purge gas.


We exclusively use cooling devices from renowned German
manufacturers. The cooling devices are connected to the overriding
controls and are monitored constantly.


The carrier structure was completely adjusted for the dynamics of the module. It
uses modular steel carriers filled with concrete polymer to ensure rigidity and
a high level of vibrational stability. One enormous advantage is that the structure
is completely detached from the rest of the cab.


The system is operated via an overriding PC control unit that is
already used for cutting components in our standard FLACS
system. This control unit is well-known by our customers world-
wide and has been proven in practice. The system can be
completely operated through this control unit, and it also allows
you to monitor the process.


ABB’s RobotStudio offline programming system allows the entire system to
be programmed offline. Section analyses, cycle time calculations and pro-
cess optimizations can be carried out this way. Naturally, the programs can
be transferred to the original system in order to complete the program-
ming quickly and easily. CAD data, such as STEP, IGES and CATIA data, can
be entered and processed directly.


Adjusted components with spark pre-separators and coarse
dust separators are used as filters. The entire pipeline is
integrated into the system.


The fixtures for the remote welding systems are a core
element of the system. The fixtures are constructed, built
and started up in our facilities.