From “Blind Welding” to “Smart Welding”
The Visual Revolution in Laser Welding Monitoring
Introducing Smart Seam Tracking: A Game-Changer for Production
From “Blind Welding” to “Smart Welding” - The Visual Revolution in Laser Welding Monitoring
Smart seam tracking is revolutionizing the manufacturing industry by minimizing scrap and enhancing process stability. This innovative technology not only saves time and reduces costs but also significantly simplifies the work for shop floor employees. The robot's ability to automatically adjust its weld path results in a more stable process, making it easier to accommodate tighter tolerances and manage warping or distortion. For businesses seeking to optimize productivity through automation, smart seam tracking is the ideal solution. It is particularly beneficial for fabricators dealing with large and intricate parts. Moreover, the customization of weld paths for individual components ensures consistently high quality, making it a valuable tool for various sectors, such as wind turbines and animal-feed industry equipment. Lasermach is at the forefront of this technological advancement, incorporating smart seam tracking in its PhotonWeld Laser-welding machines. Furthermore, this innovation is adaptable for existing Lasermach Robot/Cobot Weld systems, offering a versatile solution for companies looking to enhance their welding processes.
Types of Laser Weld Seam Tracking Sensors
There are various types of laser weld seam tracking sensors,each designed for specific welding processes.
The most common types of seam tracking systems include:
Single-camera sensor:This sensor system uses a single camera to capture images of the seam and guides the welding torch accordingly.
Stereoscopic camera sensor:This system incorporates two cameras positioned at a distance,capturing images of the seam from different angles.The captured images are then processed to provide an accurate representation of the seam's position.
Triangulation sensor:This system projects a laser beam onto the seam surface and uses a camera to measure the reflection for determining the seam's position.Triangulation sensors are suitable for detecting seams that may be challenging for other sensors to identify.
Vision sensor:Equipped with a high-resolution camera and powerful image processing software,this sensor provides accurate seam tracking.
Working Principles of Laser Weld Seam Tracking Sensors
The position between the laser sensor and the PhotonWeld laser welding gun is fixed. The sensor extracts the weld features by scanning the geometric information of the weld and workpiece through the beam, then generating three-dimensional points cloud data, and calculating the relationship between the laser welding tool of robot and the sensor, which can be used to transform the sensor data to the welding robot/cobot coordinate system. As a result, the cobot/robot is guided to automatically compensate the deviation between the teaching path and the actual weld position, so as to realize a perfect alligned welding result done with intelligent welding.
Laser weld seam tracking sensors operate by capturing images of the seam and analyzing them to determine the seam's position.The sensor is mounted on the welding torch or an independent robotic arm that follows the welding torch. A laser beam is projected onto the seam surface,and the camera captures images of the reflected laser beam. Advanced image processing algorithms are then employed to analyze the captured images and determine the seam's position.
Different technologies are utilized to capture images of the weld seam. For instance,stereoscopic camera sensors use triangulation to determine the seam's position,while vision sensors employ image processing software to analyze images. The accuracy of the sensor depends on the chosen technology, camera resolution, and the complexity of the software.
𝗦𝗲𝗮𝗺 𝗧𝗿𝗮𝗰𝗸𝗶𝗻𝗴 𝗳𝘂𝗻𝗰𝘁𝗶𝗼𝗻
Say goodbye to bad welds caused by fit-up tolerances. With the Seam Tracking function, your cobot will automatically follow the weld seam in real time, without extra sensors.
With the laser tracking system we ensure optimal adaptive welding!
Benefits of Using Laser Weld Seam Tracking Sensors: It is the best solution to increase your productivity and cost efficiency.
It is the best solution to increase your productivity and cost efficiency.
Enables adaptive welding
Improved Precision: Laser weld seam tracking sensors provide a high level of accuracy,ensuring precise welding along the tracked path.This eliminates the need for manual adjustments,ensuring consistent welds and enhancing quality while reducing scrap rates.
Increased Production Efficiency: Laser weld seam tracking sensors automate the welding process,thereby improving production efficiency.The sensors guide the welding torch,reducing welding time and increasing output.
Cost Savings: These sensors reduce the need for manual adjustments,lowering labor costs.They also enhance weld consistency and quality,reducing scrap rates and material costs.
Enhanced Safety: Laser weld seam tracking sensors improve safety by minimizing the need for manual adjustments.By guiding the welding torch,the sensors reduce the risks of human errors and injuries.
The fastest, smartest and most reliable way of welding
Reliable tracking of the welded joint
Automatic corrections of the programmed robot path
Maximum flexibility
Seam Tracking
- Adopt intelligent real-time seam tracking technology, non-contact tracking method
- Measure the deviation of the welding seam through the sensor, guide and control the welding gun positioning
- Avoid welding defects caused by workpiece position deviation, thermal deformation, etc.
- Improve production efficiency and product quality.
Composition and Principle
- Consists of lasers, optical sensors and central processing units, adopting the principles of official communication and imaging
- Get the position information of each point in the laser scanning area
- Through complex program algorithms, complete online real-time monitoring of welds.
Features
- No need for industrial computer
- Anti-arc, anti-splash, anti-smoke
- Reduce programming work for complex workpieces
- Accurately identify and detect the absolute position data of the weld