bielomatik Leuze GmbH & Co.KG

Welding SCR Containers Precisely and Leakproof for Clean Air

High-productivity welding of urea containers

Mature welding processes and flexible system concepts ensure perfect exhaust gas treatment in diesel engines.

At the K trade fair in Düsseldorf, bielomatik is presenting an automated system for process-reliable joining of SCR containers for synthetic urea. They are needed for the selective catalytic reduction process to reduce nitrogen oxides in diesel exhausts.
The very high creep capability and extreme mechanical requirements due to freezing of the urea require an absolutely reliable and leakproof welding!
To achieve this, bielomatik has developed special system concepts for prototypes and small series as well as for large series production. Adapted to the geometries and materials of the containers, the systems work with heating element welding – as shown at the trade fair – and also with infrared or spin welding, depending on the application and task. The Neuffen-based manufacturer assists users in selecting the right process and appropriate automation. From manual or partially automated assembly of parts up to completely automated system concepts with robots, the company develops carefully adapted solutions in consultation with its customers. Even highly productive systems with few operators can be flexibly designed for different container variants. To ensure that containers can be joined economically and absolutely process-reliably, bielomatik even advises on the design of container geometries. For welding seam geometries that are as favourable as possible for economical welding processes can already be established in the concept phase. In doing so, the experts also make use of their experience in welding fuel tanks collected over many years.

With the selective catalytic reduction (SCR) process, vehicle manufacturers reduce emissions of nitrogen oxides.
This is the only way that vehicles can meet future statutory specifications, among others the Euro-5 standard for commercial vehicles, the Tier-3b standard for agriculture machines and, for cars, the very strict American BIN5 exhaust standard and the new Euro-6 standard.
The urea storage and supply system mainly consists of a container for urea, a feed unit (pump), a filter and a heater. There are different designs, such as with separate or integrated pumps and filters, depending on the use – commercial vehicles, cars, agricultural and construction machines. The urea containers made of plastic always form the basis. They can be made using injection and blow moulding or rotational sintering.
For injection moulding, two halves must be joined. To achieve devices that are as compact as possible, there are concepts with direct integration of the supply system. It is therefore necessary with all production procedures to join two (or more) plastic parts into containers, depending on the design with integrated supply systems. Here, bielomatik develops production concepts that are best adapted to the user's needs, based on its strong process know-how in all technically feasible welding processes.

One Company - All Technologies …

… is the trade fair motto of bielomatik. The Neuffen-based machine builder has mastered the widest array of welding processes and so can offer optimal solutions for almost all technically used plastics. In scientific projects and its own R&D, bielomatik develops solutions and concepts for the high-performance plastics which are penetrating the “welding market” more and more, including fibre-reinforced lightweight construction materials (organic sheets) and high-temperature plastics (PPA, PPS, etc.). The spectrum includes contact heating elements, contact-free infrared heaters with short and medium wavelengths, low- and high-frequency vibration welding systems, hot gas, heat contact and high-frequency processes. Ultrasonic procedures can also be designed and integrated into special applications. With their comprehensive know-how from several decades of experience, the Neuffen-based experts will advise you individually and competently, select the appropriate procedure and create an optimal configuration. And so production operations, from compact laser-integration modules to comprehensive automated systems for large parts with several combined welding processes, obtain joining technology that is carefully adapted to their needs.

Picture: System automated with robots for high-productivity welding of urea containers for the SCR process for exhaust treatment