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On The Fly System

The On The Fly System performs laser processing by tracking moving products in real time without stopping the line. It enables continuous production on conveyors, robots, or transfer systems without stopping the product, and corrects the weld path in real time to position and speed via encoder and scan-head control. It is designed to maximize productivity and ensure consistent weld quality in high-volume, high-speed, high-precision applications such as secondary batteries and automotive electrical components.

  • Maximum productivity with non-stop production
  • Micron-level precision
  • Greater equipment and process flexibility
  • Lower defect and rework costs
  • Enhanced traceability
On The Fly System

Key Features

Real-Time Path Tracking

Scan head is automatically corrected to product position and speed while in motion.

High-Speed, High-Precision Laser Processing

Consistent bead shape and penetration at high speed without stopping the line.

Vision Alignment (Option)

Camera-based recognition automatically corrects weld position and pattern.

Various Weld Patterns

Supports custom patterns: straight, curved, serpentine, spiral, and more.

Process Monitoring & Quality Data

Integrates with LWM and integrated history management for quality data.

Flexible Line & Equipment Interface

Communicates work orders, status, and inspection results with PLC, MES, and more.

Applications

Secondary Battery

Cylindrical, prismatic, pouch cell tab/electrode and can welding; module and pack busbar, terminal, frame welding and processing

Automotive & Electrical Components

Hairpin motor, inverter/converter contacts, sensor housing, connector terminals, and other electrical component welding and processing

Electronics & Precision Parts

Fine metal parts for mobile, wearable, and IT devices; connector, terminal, and thermal management part welding and processing

Specifications

Category Item Spec
Basic System Type On-The-Fly Laser Welding
Application Electrode / tab / can / hairpin welding
Materials Cu / Al / Ni / SUS / Invar
Laser Laser Type Fiber / Green / UV
Power Range 200 W – 3 kW
Wavelength 1064 nm (standard)
Spot Size 20 – 200 μm
OTF Tracking Max Line Speed 60 – 120 m/min
Real-Time Correction < 1 ms
Weld Path Error ±10 μm or better
Position Repeatability ±5 μm
Vision Option Alignment 2D / 3D Vision Alignment
Recognition Accuracy ±3 μm
Correction Rate 120 – 240 fps
Quality Monitoring LWM Sensor Melt Pool / Plasma
Data Rate 50 – 100 kHz
Defect Detection Real-Time Defect Detection
Control / Interface Communication EtherCAT / Ethernet
UI Real-Time Welding Visualization
Line Interface MES / Factory Automation
Installation Power AC 220 / 380 V
Cooling Chiller
Operating Temperature 10 – 35°C