Tangshan Intelligent laser technology Co., Ltd.

The Future of Welding: Innovations in Weld Seam Tracking Sensors(2024年06月07日)

Intelligentlaser — 2024-07-06T12:54:56+0900

https://www.intelligent-laser.com/the-future-of-welding-innovations-in-weld-seam-tracking-sensors.html

Welding has come a long way from the days of manual welding torches and human precision. Today, welding is a highly advanced and automated process, thanks to innovations in technology and the integration of cutting-edge equipment. One such innovation that's transforming the welding industry is the evolution of weld seam tracking sensors. In this blog, we'll explore the future of welding and the exciting innovations in welding seam tracking sensors that are making it possible.

A Glimpse into Welding's Past
Welding is an ancient practice, with its origins dating back thousands of years. Traditionally, skilled welders used their expertise to join metals, a craft that relied heavily on manual precision. However, the welding landscape has evolved dramatically in recent decades.

The Role of Weld Seam Tracking Sensors

Weld seam tracking sensors have played a pivotal role in the evolution of welding technology. These sensors have become increasingly sophisticated, offering real-time monitoring and dynamic adjustments to welding processes. While they have already revolutionized the industry, the future holds even more exciting innovations.

The Innovations on the Horizon

Enhanced Sensing and Accuracy

The future of weld seam tracking sensors will see enhanced sensing capabilities, enabling even higher levels of accuracy. Advanced sensors will be able to detect and track seams with unprecedented precision, reducing the margin for error to near zero.

Integration of Artificial Intelligence
Artificial intelligence (AI) is making its mark in the welding industry. Weld seam tracking sensors will be equipped with AI algorithms that can adapt to changing conditions and provide real-time insights for optimal weld quality. These AI-driven sensors will be able to anticipate potential issues and make adjustments proactively.

Seamless Integration with Robotic Welding Systems
The integration of weld seam tracking sensors with robotic welding systems is a game-changer for industries where automation is prevalent. These sensors will work in harmony with robots, ensuring that the welding process remains precise and efficient, even when dealing with complex workpieces.

Predictive Maintenance
In the future, weld seam tracking sensors will not only track the weld seam but also the condition of the welding equipment. They will be capable of predicting maintenance needs, helping to prevent breakdowns and costly downtime.

Improved Data Analytics

The data collected by weld seam tracking sensors will be used for more in-depth analysis. This will lead to better insights into welding processes, helping companies optimize their welding procedures, reduce waste, and enhance productivity.

Applications of Advanced Weld Seam Tracking Sensors

As these innovations unfold, advanced weld seam tracking sensors will find applications in a wide range of industries and processes, including:

Automotive Manufacturing: Ensuring the precision and quality of welds in vehicle production.

Aerospace Industry: Meeting stringent safety and quality standards for aircraft components.

Construction and Infrastructure: Welding structural components with greater accuracy and reliability.

Energy Sector: Welding pipelines and critical infrastructure for the oil and gas industry.

The future of welding is bright, with innovations in weld seam tracking sensors leading the way. These sensors are propelling welding into an era of unprecedented precision, efficiency, and adaptability. As they become more sophisticated and integrated with AI and other advanced technologies, weld seam tracking sensors are transforming industries that rely on welding for critical applications. This evolution not only ensures high-quality welds but also opens doors to new possibilities in manufacturing and construction.

For more information about servo robot laser seam tracker and seam tracking welding, please feel free to contact us!

The Development of Welding Seam Tracking Technology(2024年06月06日)

Intelligentlaser — 2024-07-06T12:53:57+0900

https://www.intelligent-laser.com/the-development-of-welding-seam-tracking-technology.html

In the current welding production process, different products usually need specific welding equipment and fixtures, and different types of production lines and production processes need to be designed. Even similar products usually need to change fixtures due to different models. At the same time, there are assembly errors in the assembly process of workpieces and machining errors in the machining process, which will lead to differences between the actual welded workpieces and the design drawings, and poor consistency of workpieces. For robot welding, simple teaching usually has a big error. Thermal deformation in the welding process will also cause errors, resulting in welding defects. The above problems are common in general industrial production, which requires the automatic welding production line to have the ability to accurately position the workpiece and correct the deviation. At the same time, in the welding process, it can detect the weld in real time, adjust the welding path, correct the welding deviation and ensure the welding quality. This can also greatly reduce the workload of operators, improve the welding efficiency, reduce the manufacturing cost and realize intelligent flexible manufacturing.

Development course of weld deviation tracking technology
A key technology of intelligent welding is to realize automatic positioning and real-time tracking of workpieces and welds. In the early days, due to the backwardness of basic technologies related to detection and computer, it was difficult to realize the technology of welding seam positioning and tracking. The factory usually only designed and produced precise fixtures, and at the same time, it raised the requirements for assembly. However, for small batch production, this method was usually difficult to realize.

Since 1970s, the technology of welding seam location and detection has developed to some extent. There are two main developments. On the one hand, mechanical contact copying tracking has been developed. Mechanical copying tracking has a wear problem after a long time of use, and its accuracy is low, so its application is limited. It is usually used in scenes with low requirements for welding accuracy. On the other hand, based on the principle of arc sensing, researchers have realized real-time arc tracking and welding wire touch location. However, arc tracking usually requires the welded workpiece to be fillet weld and swing welding, which also limits the application scope of arc tracking.

After 2000, with the development of information technology, embedded processing technology, sensor technology and image processing technology, foreign researchers have made great progress in the field of non-contact real-time tracking, and formed the ability of productization. After 2010, enterprises, schools and scientific research institutions in China have gradually carried out in-depth research and development on non-contact welding seam tracking technology. At the same time, with the maturity and popularization of robot application, welding seam tracking technology has made a breakthrough development and gradually matured.

The laser structured light detection method based on the principle of triangulation is widely used because of its high contrast, high precision, strong real-time and non-contact. In practical use, there are many types of laser structured light, such as single-line structured light, multi-line structured light, circular and elliptical structured light, lattice and so on. Single-line structured light is the most widely used. The weld tracker based on single-line structured light has the characteristics of simple structure, good real-time performance and high cost performance. Now it has been used in the fields of weld tracking, weld locating and so on, and it is also the development direction of weld detection and tracking in the future.

Conclusion of welding seam tracking technology
Compared with other welding seam tracking technologies, the welding seam positioning and real-time tracking technology based on laser structured light has wider application scenarios and higher real-time and accuracy. In the future, welding seam tracking based on laser, especially 3D imaging technology, is bound to have a broader development in the field of intelligent welding.

For more information about smart laser sensor and laser brazing machine, please feel free to contact us!

The 25th Beijing Essen Welding & Cutting Fair(2024年06月05日)

Intelligentlaser — 2024-07-06T12:53:00+0900

https://www.intelligent-laser.com/the-25th-beijing-essen-welding-cutting-fair.html

Beijing Essen Welding and Cutting Fair is one of the world famous welding Fairs.

For more information about seam tracking system and robotic seam tracking, please feel free to contact us!

Transformer Corrugated Tank(2024年06月04日)

Intelligentlaser — 2024-07-06T12:52:01+0900

https://www.intelligent-laser.com/seam-tracking-system-in-transformer-corrugated-tank-welding.html

Based on visual inspection technology, Intelligentlaser has developed a visual seam tracking + parametric programming solution for corrugated tank transformer. The intelligent welding solution for corrugated transformer tank is composed of a laser sensor, a host control unit, a CUTEWELDER software system. After the configuration, the sensor can pre-scan the workpiece and then form a profile of the workpiece feature points. The users can plan the robot path according to the feature point. Therefore, they can realize many welding process such as, the reciprocating welding and intermittent welding to improve the efficient.

For more information about welding seam tracking system and robotic seam tracking, please feel free to contact us!

Intelligent Solutions(2024年06月03日)

Intelligentlaser — 2024-07-06T12:51:13+0900

https://www.intelligent-laser.com/seam-tracking-system-intelligent-solutions/

Steel Structures
Aiming at the workpiece made of steel with complex structure and large error, the laser vision seam tracking system is used to assist customers in realizing parameterized programming.

Special Vehicles Box Plate
For the complex workpiece of Special Vehicles Box Plate of the carriage board and large errors, the laser vision seam tracking system is used to assist customers in realizing parameterized programming.

Corrugated Plate
Through the laser vision seam tracking system, the welding seam profile is pre-scanned to realize path planning and parameterized programming.

Transformer Corrugated Tank
Through the laser vision seam welding tracking system, the welding seam profile is pre-scanned to realize the repeated path planning.

Micro Circumferential Weld of Pressure Vessel
Through the intelligent track systems + adaptive image algorithm, precise visual guidance is realized under the working conditions of micro-gap, welding point interference, and unstable joint.

Shrimp Waist
Aiming at the workpiece whose shape are like shrimp waist with micro-gap, tack interference and unstable target point , the laser vision seam tracking system + adaptive image algorithm is used to provide accurate visual guidance.

Aluminum Alloy Tank
Through laser vision seam tracking system and anti-reflection algorithm, high-reflection workpiece can be detected.

Friction Stir
Accurate path measurement of blank welds through laser vision seam tracking system.

Medium and Heavy Plate
Through the laser vision seam tracking system, the outline of the joint is traced, and the path planning and parameterized programming are realized.

Special Machine Seam Tracking
The solution combines the Intelligentlaser seam tracking system and PLC or its controller, driving the XY linear to finish all the automation job.

For more information about seam tracking vision in welding and seam tracking sensor, please feel free to contact us!

Steel Structures(2024年06月02日)

Intelligentlaser — 2024-07-06T12:50:34+0900

https://www.intelligent-laser.com/seam-tracking-system-in-steel-structures-welding.html

The intelligent welding solution for the steel structure is composed of a laser sensor, a host control unit, a CUTEWELDER software system. Compared with welding only by robot, with our solution, the user just needs to enter the feature parameters of the workpiece. Then the steel tracking system will guide the robot as an eye to tracking and correcting the path of the robot to realize intelligent welding. With our system, the shape of the welding is pretty, and the pass rate can reach 10% to 30%. The operation is easy and no need to repair after which lower the cost greatly.

For more information about weld seam tracking sensor and laser tracking cost, please feel free to contact us!

Micro Circumferential Weld of Pressure Vessel(2024年06月01日)

Intelligentlaser — 2024-07-06T12:49:32+0900

https://www.intelligent-laser.com/seam-tracking-system-in-micro-circumferential-weld-of-pressure-vessel-welding.html

Micro Circumferential Weld of Pressure Vessel
Based on visual inspection technology, Intelligentlaser has developed a visual seam tracking + parametric programming solution for pressure vessel circumferential seam welding requirements. The intelligent welding solution for the pressure vessel is composed of a laser sensor, a host control unit, a CUTEWELDER software system. With our solution, the user just needs to enter the feature parameters of the workpiece. In the meantime, the image algorithm inside the CUTEWELDER software system can also shield the interference of the joints, adjust the welding process automatically. Therefore, our solution can help weld accurately even the torch is changing all the time. This intelligent solution supports many tracking ways, such as laser tracking. The accuracy of the tracking weld can reach +-0.1mm. Moreover, the solution can be used for high-reflective workpiece such as stainless steel, aluminum alloy and polished metal, etc.

For more information about laser seam tracking system and arc tracking, please feel free to contact us!

Micro Circumferential Weld of Pressure Vessel(2024年06月01日)

Intelligentlaser — 2024-07-06T12:48:53+0900

https://www.intelligent-laser.com/seam-tracking-system-in-micro-circumferential-weld-of-pressure-vessel-welding.html

For more information about laser seam tracking system and arc tracking, please feel free to contact us!

Oil and Gas Innovation: Arc Products Seam Tracker's Impact on Pipeline Welding(2024年04月10日)

Intelligentlaser — 2024-04-10T15:45:09+0900

https://www.intelligent-laser.com/

In the ever-evolving landscape of the oil and gas industry, technological advancements play a pivotal role in enhancing efficiency, safety, and precision. One such innovation making waves in pipeline welding is the Arc Products Seam Tracker. This cutting-edge technology is revolutionizing the way pipelines are constructed, ensuring a seamless and robust infrastructure for the energy sector.

Unraveling the Essence of Arc Products Seam Tracker

Precision in Every Weld

The arc products seam tracker is designed to bring a new level of accuracy to pipeline welding. With its state-of-the-art tracking system, it follows the weld joint seamlessly, ensuring that each weld is executed with unparalleled precision. This not only enhances the overall structural integrity of the pipeline but also minimizes the need for rework, saving both time and resources.

Efficiency Redefined

Time is of the essence in the oil and gas industry, and the arc products seam tracker is acutely aware of this. By automating the welding process and reducing the reliance on manual labor, this innovative technology significantly accelerates the pace of pipeline construction. Projects that once took weeks can now be completed in a fraction of the time, contributing to increased productivity and faster project delivery.

Adaptable to Varied Conditions

Pipeline construction often involves challenging terrains and adverse weather conditions. The arc products seam tracker is built to thrive in such environments. Its adaptability to varying conditions ensures that pipeline welding can proceed smoothly, regardless of the external challenges posed by the surroundings. This adaptability not only improves the efficiency of the welding process but also enhances the safety of on-site workers.

Real-world Applications

Subsea Pipelines

In the realm of offshore oil and gas exploration, subsea pipelines are a lifeline for transporting hydrocarbons. The arc products seam tracker's ability to operate in underwater conditions makes it a game-changer for subsea welding. It ensures that welds are executed with precision even in the depths of the ocean, contributing to the reliability and longevity of subsea pipelines.

Remote Areas and Harsh Environments

Oil and gas reserves are often located in remote areas with challenging environmental conditions. The arc products seam tracker's adaptability to harsh terrains and extreme weather makes it an invaluable asset in constructing pipelines in such regions. It facilitates efficient welding operations, even in the most unforgiving environments, ensuring the robustness of the infrastructure.

Long-distance Pipelines
The construction of long-distance pipelines demands a high level of accuracy to maintain the structural integrity over vast expanses. Arc products seam tracker's precision-tracking system proves indispensable in such scenarios. It guarantees that each weld is executed with meticulous detail, contributing to the overall reliability of the pipeline over extensive distances.

In conclusion, the arc products seam tracker is not just a technological marvel; it is a transformative force in the realm of pipeline welding within the oil and gas industry. Its impact is felt in the form of enhanced precision, improved efficiency, and adaptability to diverse conditions. As the energy sector continues to evolve, innovations like the arc products seam tracker stand as testament to the industry's commitment to progress and excellence in infrastructure development. With its seamless integration into pipeline construction, this technology is set to shape the future of oil and gas exploration and transportation.

Intelligent Laser provides seam tracking sensor, robotic vision systems, robot vision system, robotic vision, laser seam tracking system, etc. For more information, please feel free to contact us!

Precision Unleashed: How Laser Brazing Machines Enhance Power Equipment Performance(2024年04月10日)

Intelligentlaser — 2024-04-10T15:43:57+0900

https://www.intelligent-laser.com/seam-tracking-system-intelligent-solutions/

In the dynamic realm of power equipment manufacturing, precision is paramount. Laser brazing machines have emerged as transformative tools, revolutionizing the industry's approach to welding and enhancing overall performance. This blog will delve into the intricacies of how these cutting-edge machines are unleashing a new era of precision in power equipment.

Unveiling the Technology

Understanding Laser Brazing

Laser brazing involves the use of high-powered lasers to melt and join metals with remarkable accuracy. Unlike traditional welding methods, laser brazing minimizes heat-affected zones and produces cleaner, more precise welds. This technology is gaining widespread acceptance in the power equipment sector due to its ability to deliver superior results with unparalleled precision.

Advantages in Power Equipment Manufacturing

Enhanced Structural Integrity

Laser brazing machines contribute to the structural integrity of power equipment by creating strong, reliable welds. The precision offered by these machines ensures that the components fit seamlessly, reducing the risk of weak points or structural vulnerabilities.

Minimized Distortion

Traditional welding methods often result in distortion due to the intense heat generated during the process. Laser brazing machines, on the other hand, minimizes distortion, preserving the original shape and dimensions of the power equipment components. This characteristic is crucial for maintaining the efficiency and functionality of the machinery.

Improved Aesthetics

Beyond functionality, the aesthetic appeal of power equipment is a significant consideration. Laser brazing machines produces aesthetically pleasing welds with minimal spatter and clean finishes. This not only enhances the overall appearance of the equipment but also reflects a commitment to quality craftsmanship.

Efficiency Redefined

Increased Production Speed

Laser brazing machines contribute to improved efficiency in power equipment manufacturing by reducing processing time. The precision and speed of laser technology allow for faster production cycles without compromising on the quality of welds. This results in a more streamlined manufacturing process and increased output.

Cost-Effective Solutions

While the initial investment in laser brazing technology may seem substantial, the long-term benefits outweigh the costs. The efficiency, precision, and reduced need for post-welding treatments contribute to significant cost savings over time, making laser brazing an economically viable choice for power equipment manufacturers.

In conclusion, the advent of laser brazing machines has ushered in a new era of precision in power equipment manufacturing. The advantages, from enhanced structural integrity to increased production speed, position laser brazing as a game-changer in the industry. As manufacturers continue to seek innovative solutions, the role of laser brazing in enhancing power equipment performance cannot be overstated. It's a precision revolution that is reshaping the future of power.

Intelligent Laser provides laser vision system, robot welding, robotic welding system, robot laser welding machine, robotic vision systems, etc. For more information, please feel free to contact us!

The Role of Laser Brazing Machines in Steel Joinery(2024年04月10日)

Intelligentlaser — 2024-04-10T15:43:00+0900

https://www.intelligent-laser.com/

In the dynamic world of manufacturing and construction, advancements in technology continue to reshape traditional processes. One such innovation making waves in steel joinery is the use of laser brazing machines. These cutting-edge devices are transforming the way steel components are joined, offering precision, efficiency, and durability. In this blog post, we'll explore the fascinating realm of laser brazing machines and their pivotal role in revolutionizing steel joinery.

Understanding Laser Brazing Technology

Laser Brazing involves the use of high-energy laser beams to melt and fuse metal surfaces, creating a seamless and robust joint. Unlike traditional welding methods, laser brazing minimizes heat-affected zones, reducing the risk of distortion and ensuring a high-quality finish. This technology has found its niche in the intricate world of steel joinery, where precision is paramount.

Precision Redefined: Laser Brazing in Steel Joinery

Precision is the hallmark of laser brazing machines, making them indispensable in steel joinery applications. The focused laser beam allows for pinpoint accuracy, ensuring that the joint is created with meticulous detail. This precision is especially crucial in industries where structural integrity and aesthetic appeal go hand in hand, such as automotive manufacturing and architectural steelwork.

Efficiency Unleashed: Streamlining Steel Joinery Processes

Gone are the days of time-consuming and labor-intensive welding processes. Laser brazing machines have ushered in a new era of efficiency in steel joinery. The speed at which these machines operate significantly reduces production time, enabling manufacturers to meet tight deadlines without compromising on quality. This efficiency is a game-changer for industries that demand both speed and accuracy in their steel joinery projects.

Durability by Design: Laser-Brazed Joints Stand the Test of Time

The durability of laser-brazed joints is a testament to the reliability of this cutting-edge technology. The precision and controlled heat input result in joints that boast superior strength and longevity. Whether used in the construction of bridges, high-rise buildings, or heavy machinery, laser-brazed joints can withstand the rigors of time and environmental factors, ensuring a lasting connection.

Versatility in Applications: Beyond the Boundaries of Traditional Welding

Laser brazing machines are not limited to specific steel types or thicknesses. Their versatility allows them to be employed in a wide range of applications, from thin-gauge automotive components to thick structural steel elements. This adaptability opens up new possibilities for engineers and manufacturers, providing them with a flexible tool for various steel joinery challenges.

As technology continues to evolve, so does the landscape of steel joinery. Laser brazing machines are at the forefront of this transformation, offering unparalleled precision, efficiency, durability, and versatility. Manufacturers and engineers embracing this cutting-edge technology are not only redefining the way steel components are joined but also shaping the future of industries that rely on the strength and integrity of steel structures.

In a world where innovation is key, laser brazing machines stand as a testament to human ingenuity, pushing the boundaries of what is possible in the realm of steel joinery. As these machines become more widespread, we can expect to see even more groundbreaking developments in the field, solidifying their role as indispensable tools in the hands of those shaping the steel structures of tomorrow.

Intelligent Laser provides seam tracker, laser vision system, laser seam tracking, robot machine vision, laser vision system, etc. For more information, please feel free to contact us!

The Art and Science of Laser Brazing Machine: Elevating Sheet Metal Joining to New Heights(2024年04月10日)

Intelligentlaser — 2024-04-10T15:42:16+0900

https://www.intelligent-laser.com/

In the dynamic world of sheet metal fabrication, precision and efficiency are paramount. As technology continues to advance, so does the methodology behind joining sheet metal. One groundbreaking innovation that has taken center stage is the art and science of laser brazing machines. In this blog, we will delve into the transformative impact of laser brazing machines, exploring how they elevate sheet metal joining to new heights.

The Art of Precision

Laser brazing machine is an art form that brings a level of precision previously unmatched in sheet metal joining. Traditional welding methods often result in excess material and uneven seams. Laser brazing machines, on the other hand, allows for meticulous control over the heat application, minimizing distortion and ensuring a flawless finish. The art lies in the ability to craft intricate joints with unparalleled accuracy, enhancing the aesthetic appeal of the final product.

The Science Behind the Brilliance

At the core of laser brazing machines is cutting-edge science that harnesses the power of focused laser beams. These machines utilize advanced optics and control systems to deliver concentrated heat precisely where it's needed. The science of laser brazing machines lies in the ability to achieve optimal temperature gradients, facilitating the bonding of metals without compromising the structural integrity of the sheet. This controlled process results in stronger, cleaner joints, setting a new standard in sheet metal fabrication.

Elevating Efficiency to New Heights

One of the key advantages of laser brazing machines is its remarkable efficiency. Traditional welding methods often require extensive post-processing, including grinding and polishing to achieve a smooth finish. Laser brazing machines minimizes the need for such labor-intensive tasks, saving time and resources. The efficiency gains extend beyond the production floor, impacting overall project timelines and reducing costs associated with manual finishing.

Versatility Unleashed

The versatility of laser brazing machines is a testament to their prowess in sheet metal joining. Whether working with thin or thick sheets, the adaptability of these machines allows for a wide range of applications. From automotive components to architectural elements, laser brazing machines has become the go-to solution for fabricators seeking a versatile, high-quality joining method.

In the ever-evolving landscape of sheet metal fabrication, the art and science of laser brazing machines have emerged as a transformative force. Precision, efficiency, and versatility are no longer aspirations but achievable benchmarks. As we witness the elevation of sheet metal joining to new heights, it's clear that laser brazing machines is not just a technology; it's a game-changer, setting the stage for a future where the boundaries of what's possible continue to expand.

Intelligent Laser provides laser brazing machine, laser seam tracking system, robotic seam tracking, intelligent laser, intelligent laser, etc. For more information, please feel free to contact us!

Welding Innovation: Laser Seam Welders in the Electronics Industry(2024年04月10日)

Intelligentlaser — 2024-04-10T15:41:28+0900

https://www.intelligent-laser.com/seam-tracking-system-intelligent-solutions/

In the fast-paced world of electronics manufacturing, precision and efficiency are paramount. Traditional welding methods often fall short of meeting the rigorous demands of the industry. Enter laser seam welders, a cutting-edge technology revolutionizing the way electronic components are assembled. This blog delves into the innovative applications of laser seam welders in the electronics industry, highlighting their role in shaping the future of electronic manufacturing.
The Power of Precision
Microscopic Welding
Laser seam welders bring a level of precision to electronic component welding that was once unimaginable. With focused laser beams, manufacturers can achieve microscopic welds, ensuring the integrity of delicate electronic parts without compromising their functionality. This precision is particularly crucial in the production of compact devices such as smartphones, wearables, and medical devices.

Reduced Heat Impact

Unlike traditional welding methods that may subject electronic components to excessive heat, laser seam welders operate with minimal heat impact. This is a game-changer for sensitive electronic parts that can be damaged by high temperatures. The ability to create strong, reliable welds without risking thermal damage is a significant advancement in electronics manufacturing.

Streamlining Production Processes

High-Speed Welding

In the competitive landscape of electronics manufacturing, speed is of the essence. Laser seam welders offer high-speed welding capabilities, significantly reducing production time. This acceleration in the welding process contributes to increased throughput, allowing manufacturers to meet the growing demand for electronic devices in a timely manner.

Automation Integration
Another aspect of the innovation brought by laser seam welders is their seamless integration into automated production lines. The technology lends itself well to robotic welding systems, facilitating efficient and consistent welding across large batches of electronic components. This integration not only improves production efficiency but also reduces the margin of error in the welding process.

Ensuring Quality and Reliability

Hermetic Sealing for Electronics

Electronic devices often require hermetic sealing to protect them from environmental factors such as moisture and dust. Laser seam welders excel in creating tight, reliable seals, ensuring the longevity and performance of electronic components. This is particularly crucial in applications like sensors, communication devices, and aerospace electronics.

As the electronics industry continues to evolve, innovations like laser seam welders play a pivotal role in shaping its trajectory. The precision, speed, and reliability offered by this advanced welding technology make it an invaluable asset in the production of electronic components. From microscopic welds to hermetic seals, laser seam welders are at the forefront of welding innovation, ensuring that the electronic devices we rely on are not only cutting-edge but also built to last.

Intelligent Laser provides machine vision, laser seam tracking welding, laser welding robot system, robotic welding system, robotic vision, etc. For laser tracking cost or more information, please feel free to contact us!

Precision Unleashed: Exploring Laser Seam Welders in Automotive Manufacturing(2024年04月09日)

Intelligentlaser — 2024-04-10T15:38:49+0900

https://www.intelligent-laser.com/seam-tracking-system-intelligent-solutions/

In the ever-evolving landscape of automotive manufacturing, precision and efficiency are paramount. One technology that has revolutionized the welding process in this industry is the laser seam welder. This blog delves into the intricacies of how laser seam welders are unleashing precision in automotive manufacturing, reshaping the way vehicles are built.

The Cutting-Edge Technology Behind Laser Seam Welders

Laser Precision in Welding
Laser seam welders employ cutting-edge laser technology to achieve unparalleled precision in the welding process. This method allows for the creation of seamless and high-strength joints in automotive components, ensuring structural integrity and durability.

Versatility in Materials
One of the key advantages of laser seam welders is their ability to weld a variety of materials commonly used in automotive manufacturing. From traditional metals like steel and aluminum to advanced alloys, laser seam welders provide a versatile solution, accommodating the diverse materials used in modern vehicle construction.

Applications in Automotive Manufacturing

Body-in-White Assembly
Laser seam welders play a vital role in the assembly of the "body-in-white," the stage where the vehicle's structural shell is constructed. The precision offered by laser technology ensures tight and secure welds, contributing to the overall strength and safety of the vehicle.

Reducing Weight, Increasing Efficiency
In the pursuit of fuel efficiency and reduced emissions, automakers are increasingly turning to lightweight materials. Laser seam welders facilitate the use of such materials by ensuring that joints are not only strong but also lightweight, contributing to improved fuel efficiency without compromising safety.

Seamless Joining of Dissimilar Materials
With the trend towards multi-material structures in automotive design, laser seam welders prove invaluable in seamlessly joining dissimilar materials. This capability enables the integration of diverse materials with varying properties, allowing manufacturers to optimize performance and meet stringent industry standards.

Advantages for the Automotive Industry

Enhanced Productivity and Cost-Efficiency

The precision and speed of laser seam welders translate to enhanced productivity on the assembly line. Moreover, the reduced need for post-weld finishing and the minimal waste produced contribute to significant cost savings in the manufacturing process.

Meeting Strict Quality Standards

Automotive manufacturers adhere to stringent quality standards, and laser seam welders play a crucial role in meeting and surpassing these benchmarks. The non-contact nature of laser welding minimizes the risk of contamination, ensuring consistently high-quality welds.

As automotive manufacturing continues to push the boundaries of innovation, laser seam welders stand as a testament to the industry's commitment to precision and excellence. From lightweight materials to complex joint configurations, these advanced tools are reshaping the way vehicles are built, contributing to the production of safer, more efficient, and technologically advanced automobiles. The journey of precision unleashed by laser seam welders in automotive manufacturing is undoubtedly steering the industry towards a future of unparalleled quality and performance.

Intelligent Laser provides robotic seam tracking, seam tracking system welding, robot welding seam tracking, robot welding laser seam tracking, robotic vision, etc. For laser tracking cost or more information, please feel free to contact us!

Navigating the Future: Laser Seam Weler in Shipbuilding and Maritime Applications(2024年04月09日)

Intelligentlaser — 2024-04-10T15:38:09+0900

https://www.intelligent-laser.com/laser-seam-tracking-system-cases/

In the vast expanse of shipbuilding and maritime industries, technological advancements play a pivotal role in shaping the vessels of the future. Among these innovations, laser seam welder stands out as a cutting-edge solution, transforming the way ships are constructed. This blog explores the significance of laser seam welder in shipbuilding and maritime applications, delving into its impact on efficiency, durability, and the overall evolution of marine engineering.

The Power of Precision

Unprecedented Precision in Joining Materials

Laser seam welder introduces a new era of precision in joining materials. With focused laser beams, shipbuilders can achieve seamless and high-quality welds, ensuring the structural integrity of vessels. The precision offered by laser technology is especially crucial in the maritime sector, where the reliability of welded joints directly influences a ship's performance and safety.

Enhanced Structural Integrity

The maritime environment poses unique challenges, including constant exposure to corrosive saltwater and extreme weather conditions. Laser seam welder, with its ability to create narrow and deep welds, contributes to enhanced structural integrity. This results in ship components with superior resistance to corrosion and fatigue, ultimately extending the lifespan of vessels.

Efficiency in Shipbuilding Processes
Streamlining Production Timelines

Laser seam welder accelerates shipbuilding processes by offering faster and more efficient welding techniques. The non-contact nature of laser welding reduces the need for extensive post-welding cleanup, contributing to streamlined production timelines. Shipbuilders can meet tight schedules without compromising on the quality of welds, ushering in a new era of efficiency.

Versatility in Material Compatibility

The maritime industry relies on a diverse range of materials, each chosen for its specific properties. Laser seam welder's versatility allows shipbuilders to join different materials seamlessly, accommodating the complex requirements of modern ship designs. Whether welding steel, aluminum, or alloys, laser technology adapts to the varying demands of maritime applications.

Revolutionizing Ship Design and Functionality

Innovative Design Possibilities

Laser seam welder opens doors to innovative ship designs that were once considered challenging to execute. The ability to create intricate and lightweight structures without compromising strength empowers naval architects to explore new possibilities in vessel design. This not only contributes to aesthetic appeal but also enhances overall fuel efficiency and performance.

As we navigate the future of shipbuilding and maritime applications, laser seam welder emerges as a transformative force. From precision and efficiency to versatility and innovative design, the impact of this technology extends far beyond conventional welding methods. Embracing laser seam welder in shipbuilding is not merely a technological upgrade; it's a journey towards safer, more durable, and forward-looking vessels that will navigate the seas of the future with unmatched efficiency and resilience.

Intelligent Laser provides robotic vision systems, robot laser, machine vision, robotic vision, robot welding machine, etc. For more information about robot vision system applications, please feel free to contact us!

Basic Components and Benefits of Adding System to Robot Vision System(2024年02月20日)

Intelligentlaser — 2024-02-20T16:02:17+0900

https://www.intelligent-laser.com/basic-components-and-benefits-of-adding-system-to-robot-vision-system.html

A machine vision system can perform continuous inspections, improving product quality, increasing yield, and reducing production costs. It ensures consistent product appearance and quality while reducing unnecessary processing steps.

Machine vision refers to the automatic visual inspection of manufactured goods using industrial cameras, lenses, and lighting. Robot vision systems provide a fast and reliable way to inspect parts online. With robot vision systems, every part on a high-speed production line can be imaged and inspected to ensure 100% quality control.

Basic components of robot vision systems

A robot's vision system, also known as an automatic vision system or visual inspection system, consists of several components that are common to most systems.

The basic components of a robot vision system include the following five parts: lighting system, sensor, vision processing system, processing hardware, and software algorithms. This article will primarily focus on the lighting system, sensor, and vision processing system.

The lighting used in a robot vision system should be selected to maximize the contrast of any features being measured or observed while minimizing the contrast of all other features of the part. Achieving this goal may require altering the amount of light used, the way that it is used, and the position of the light source relative to the part and optical system or camera.

In a robotic vision system, the sensor is used to capture light from the optical system and convert it into a digital image. The sensors capture light using CMOS technology and convert it into a set of pixels that display the light in different areas of the observed object. The sensors are measured by their resolution, which indicates the number of available pixels in the digital image. Sensors with higher resolution can generate images with more pixels, which typically translate into higher image quality and stronger detail resolution.

The vision processing unit in a robot vision system extracts data from digital images, using software to perform specific functions and then evaluate the observed part. These evaluations are pre-programmed conditions that define the standards for accepting or rejecting the observed part.

Benefits of adding a robot vision system

Adding a vision system to a robot allows it to quickly locate targets within its work range, reducing the need for complex and expensive equipment. This increases the flexibility of robot automation to adapt to changes in part size, shape, and position, thereby reducing the complexity of production units. By adding a vision system, robots become practical for palletizing and depalletizing, assembling components, unloading molds, lifting parts from shelves, and removing parts from boxes. They can also track and pick up moving parts on a conveyor.

To optimize production, robots must be correctly installed with a robotic vision system, and they must coordinate with existing machinery and work units. The integrated vision system ensures the accuracy and efficiency of a robot's function and has a significant impact on the production line. The robot vision system determines the exact location of the conveyor and the robot controller adds speed information from encoders on conveyors so that the vision system can track and pick up products in motion. This eliminates the need for stopping the conveyor or using expensive fixtures.

The vision system can simplify unit designs and reduce costs, making robot automation easier to justify rather than rendering each part precisely in the same position and orientation for the robot to pick up.

Intelligent Laser provides laser brazing machine, laser seam tracking system, robotic seam tracking, intelligent laser, laser vision system, etc. For more information, please feel free to contact us!

What Are the Different Ways for Robots to Track Weld Seams?(2024年02月20日)

Intelligentlaser — 2024-02-20T16:01:09+0900

https://www.intelligent-laser.com/what-are-the-different-ways-for-robots-to-track-weld-seams.html

Welding tracking, also known as joint tracking, refers to real-time tracking of the welding position before welding. This can not only correct the trajectory of the robot or special machine, but also change the welding seam formation by adjusting the voltage, wire feeding speed, or walking speed.

Robot welding cannot meet the actual needs of some products with lower precision, so it is necessary to add a robot welding tracking system. So what are the ways of robot welding seam tracking? Next, we will briefly introduce them.

Types of robot welding seam tracking

Robot welding seam tracking includes arc tracking and laser tracking. Thick plates usually use arc tracking, mainly oscillating welding. The deviation between the welding seam and the programming is calculated by contacting the two surfaces of the welding wire and the base metal, and then welding is performed by swinging. When the welding robot is used for the first time, it generally needs to be equipped with arc tracking detection function. The welding seam can be detected before welding, or the welding seam can be detected at the same time.

The starting point detection of the welding robot can be used alone, and can only detect the deviation position of the starting point and the end point. However, arc tracking can be detected at any position. If it is a right-angle welding seam, the start detection function is basically sufficient. For most thin plates with a thickness less than 2MM, especially spliced welding seams, lasers are used as welding seam tracking.

The laser tracking uses a front-end camera to monitor the laser scanning, obtain welding information, and feedback it to the robot controller. The robot will automatically modify the trajectory based on the data obtained during the welding process to complete the welding. The robot welding seam tracking arc tracking and start detection refer to the welding wire contacting both sides of the base material, the front part of the welding wire releasing low voltage, transmitting information to the controller through sensors, and then automatically obtaining the welding seam position through calculation. When the position of the workpiece changes, the welding seam position can still be obtained through arc tracking without reprogramming.

Therefore, arc tracking and start detection are only suitable for fillet welds or lap welds (plate thickness greater than 3 mm). However, laser tracking is mainly suitable for thin plates, and the accuracy is slightly higher than arc tracking. However, laser tracking requires adding a laser to the welding head, which will cause certain interference to the product. Therefore, the welding tracking system of the robot should be selected according to the actual situation of the product.

How does robot welding seam tracking work?

When the laser stripes are irradiated on the welding surface to form laser stripes, the lens on the sensor produces a cross-sectional contour of the weld on the photosensitive detector, that is, an image of the laser stripe that reflects the shape of the weld cross-section. The visual control of the laser stripe image extracts feature data such as the coordinates of the tracking point, the gap between the welding seams, the displacement, and the cross-sectional area. The visual system calculates the welding torch path based on the measured welding position information and transmits the path data to the robot.

To ensure that the welding torch is always aligned with the welding seam, the robot controls the running path in real time. At the same time, the visual system can also calculate the required welding parameters, such as welding speed, arc voltage, welding current, swing range, etc., based on the measured welding size data.

These welding parameters can be transmitted to the robot through Ethernet, and the robot can control the welding speed and swing of the welding torch, or control the power supply of the welding machine to adjust the welding parameters, thereby achieving adaptive welding parameter control.

Intelligent Laser provides seam tracker, laser vision system, laser seam tracking, robot machine vision, laser seam tracking, etc. For more information, please feel free to contact us!

How to Achieve Automatic Weld Seam Tracking and Localization with Welding Robots?(2024年02月20日)

Intelligentlaser — 2024-02-20T16:00:28+0900

https://www.intelligent-laser.com/how-to-achieve-automatic-weld-seam-tracking-and-localization-with-welding-robots.html

The complete replacement of manual welding with welding robots is still premature, but the goal of replacing 90% of welders with welding robots in batch welding operations can be achieved. Welding robots are increasingly favored by small and medium enterprises for their advantages of high efficiency, high quality, and easy management. For some products requiring high precision, welding robots alone cannot solve the problem, so users need to add an automatic seam tracking positioning system in a timely manner.

The importance of automatic seam tracking system for welding robot configuration

In the welding production process, welding robots often encounter various technical conditions such as workpiece alignment errors, clamping deviations, and sheet metal thermal deformation. In addition, welding robots often require manual repair after welding, which not only increases labor costs but also increases the repair rate of products for small and medium-sized enterprises.

High cost of improving the workpiece feeding: updating the original processing equipment and designing with high-precision fixtures.

Users' actual production situation: welding products have many varieties, small batches, and high requirements for welding accuracy and welding technicians.

In order to improve the processing efficiency of welding robots, reduce teaching time and difficulty, and solve the positioning problem of automatic seam tracking, it is imperative.

What is automatic seam tracking and welding positioning of welding robots?

Strictly speaking, the seam tracking and positioning system of welding robots consists of two parts: before welding, the seam positioning function is used to check whether the clearance is appropriate and whether it accurately reaches the joint to be welded. Real-time seam tracking, monitoring product deformation during welding.

Seam tracking: Before the welding position data is collected, an optical sensor is installed for the welding position, which is collected by a power supply or welding parameters and then transmitted to the welding robot and various adaptive fuzzy control algorithms for adaptive control and real-time seam tracking.

Welding positioning: The process of using one or more searches to determine the position of the weld to be welded by moving the welding robot or editing the machine program path.

How to automatic seam tracking and positioning of welding robots?

There are multiple methods for the automatic seam tracking and positioning of welding robots. The commonly used methods are peripheral auxiliary detection and self-detection.

Auxiliary detection: laser tracking and photographic imaging tracking. The seam tracking and positioning control system can collect seam-related data through optical measurement equipment, and the welding robot can adjust the adaptive arm's movement trajectory through data comparison, thereby realizing real-time seam tracking.

Self-detection: Inductively test welding wire and real-time test welding parameters.

Methods for realizing the automatic seam tracking and positioning of welding robots

The seam tracking and positioning methods of welding robots have their own advantages and disadvantages. The working principles of the following two methods are summarized:

Real-time seam detection method:

The welding method of welding products is gas shielded welding and angle welding or lap welding (the thickness of the plate is greater than 3mm). The quality of seam tracking is closely related to the control algorithm and matching of the welding robot arc welding power supply.

It can reduce costs: reduce the cost of detection equipment, but the cost of welding robot body and welding equipment will correspondingly increase.

There are many limitations to the applicable welding production environment.

Laser automatic seam tracking is currently the preferred mature and reliable control method in the market

It is not limited by welding process, method, and environment.
Peripheral equipment welding robots.
Increased peripheral hardware costs.

Intelligent Laser provides robot vision system, welding tracking system, welding seam tracking system, seam tracking vision in welding, robotic vision, robot welding machine, etc. For more information, please feel free to contact us!

Weld Seam Tracking Sensor Technology Introduction(2024年02月20日)

Intelligentlaser — 2024-02-20T15:59:43+0900

https://www.intelligent-laser.com/weld-seam-tracking-sensor-technology-introduction.html

The concept of weld seam tracking system

The welding seam tracking sensor mainly consists of a CCD camera, a semiconductor laser, a laser protection lens, a splash-proof baffle, and a wind cooling device. By using the principle of triangulation, the coordinate information of each point in the laser scanning area is obtained, and the online real-time detection of common welding seams is realized through complex program algorithms, and the robot is guided to adjust the working trajectory according to the scanning data.

Manual or semi-automatic welding relies on the judgment of welding workers and the adjustment of process parameters to complete the tracking of welding seams. After the industrial robot is equipped with a weld seam tracking system, the equipment can calculate the error between the detected weld seam and the robot teaching trajectory through the sensor, and output error data, which is then corrected in real-time by the motion execution mechanism to accurately guide the welding gun to perform automatic welding. This is like giving the robot eyes.

For fully automated welding equipment such as robots or automatic welding machines, they mostly rely on the robot's teaching programming and trajectory reproduction to work, so it is necessary to ensure the accuracy of the workpiece and its assembly to ensure that the welding gun can align the welding seam within the allowed precision range of the process.

However, in many cases, the accuracy and consistency of the workpiece and its assembly cannot meet the requirements of large-scale workpieces or mass production of automated welding. At the same time, during the welding process, there are uncontrollable effects of stresses and deformations caused by overheating of the workpiece. Therefore, once encountering these situations, there is a need for an active tracking device to perform operations similar to the eyes and hands of manual welding workers, that is, the weld seam tracking system guides the equipment to work.

The principle of laser weld seam tracking
The laser weld seam tracking sensor adopts a laser triangulation reflection principle, that is, the laser beam is amplified to form a laser line projected onto the surface of the object to be measured. The reflected light passes through a high-quality optical system and is projected onto the imaging matrix to obtain the distance from the sensor to the surface of the measured object (Z axis) and the orientation information along the laser line (X axis) by calculation. Moving the measured object or the contour gauge probe can obtain a set of three-dimensional measurement values.

The obtained information can be used for welding seam searching and positioning, weld seam tracking, adaptive welding parameter control, weld seam forming inspection, and real-time transmission of information to the mechanical arm unit to complete various complex welding and prevent welding quality errors, achieving unmanned welding.

The development and prospect of weld seam tracking
The weld seam tracker can be said to be a great invention for welding. With the development of technology, achieving welding automation and intelligence has become an inevitable trend.

In the next few years, not only technology upgrades are needed for laser weld seam tracking, but also in terms of usage expansion, it is necessary to deepen the understanding of customer usage, meet user needs, and improve products.

What Are the Advantages of Robot Welding?(2024年02月20日)

Intelligentlaser — 2024-02-20T15:59:05+0900

https://www.intelligent-laser.com/what-are-the-advantages-of-robot-welding.html

Many people have misunderstandings about robot welding, thinking that it is difficult to make the leap from manual welding to automatic welding. However, in fact, robot welding can be completed through simple steps.

Since industrial robots were introduced, welding has been one of the most common tasks for robots. The world's first industrial robot, Unimate, helped the automotive industry complete spot welding in 1961. In recent years, welding robots have solved the problem of high-skilled welder shortage for many companies. According to statistics from the American Welding Society, the welding industry in the United States will face a shortage of 400,000 welders by 2024.

Industrial robots are very suitable for completing some welding processes. They not only solve the problem of shortage of skilled workers, but also greatly help improve productivity, quality, and efficiency.

However, for many companies, programming robots is a huge challenge. For small-scale tasks, the time it takes to program robots may be greater than the time it takes to complete the task manually. At this time, companies often choose to give up using robots to complete the welding task.

Fortunately, we now have a very simple way to program robots and achieve perfect welding in a short time. In this article, we will introduce 5 advantages of robot welding.

Very experienced welders can accurately meet the welding process requirements, and the welding joint is very beautiful. However, using robots to do this work can be done better. Because even the best welders cannot match the cohesion, speed, and efficiency of machines. The outstanding advantages of robot welding are as follows:

High productivity of robot welding
Robots work faster than manual operations, so the production cycle of products will be shortened. And robots do not need to rest while working, so the time saved can be used to increase production, and the output of the entire production line can be increased significantly through accumulation.

Reasonable use of technical staff for robot welding
The problem of shortage of technical staff will not be solved in a short time. The industry began to worry about the shortage of technical workers more than a decade ago, and the vacancy position of technical workers will only increase. Making full use of robot welding can better utilize technical personnel within the team.

High quality of robot welding
Even the best and most stable welding technology workers cannot beat robots. As long as the hardware equipment is set properly, robots can accurately repeat their actions and weld high-quality products every time.

High safety of robot welding
The welding process may lead to safety issues. It needs to be completed in a high-temperature, sparks, high-pressure, and high-noise environment, which may be dangerous to workers. Using machines instead of manual labor is a human-oriented modern production model.

High efficiency of robot welding
To ensure the quality of welding, manual welding points are usually larger than the welding area required by the processing technology. Unnecessary welding areas, even a little bit more than what is required by the process, can accumulate into huge costs over a long period. Studies have shown that if each weld spot is 1 millimeter wider than required, it may bring an additional $10,000/year in cost to the company.

Intelligent Laser provides seam tracking sensor, robotic vision systems, robot vision system, robotic vision, robot machine vision, etc. For more information, please feel free to contact us!

Weld seam tracking technology, the "eyes of the beholder" for industrial robots!(2023年)

Intelligentlaser — 2023-09-08T15:46:28+0900

The industrial robot market is rapidly emerging as a new engine for global manufacturing. Behind the smart manufacturing sweeping the world, the machine vision technology, known as the role of industrial robots' "golden eye", is of great merit! Laser automatic weld seam tracking system is an important equipment for welding robots to achieve intelligence.

Laser seam tracking welding system principle

Vision system, combined with laser and vision technology, can achieve accurate detection of three-dimensional space coordinate position, so that the robot to achieve independent identification, independent adjustment function, is the core component of the robot control. The system is mainly composed of laser sensors and control hosts. The laser sensors are responsible for active acquisition of weld seam information, and the control hosts are responsible for real-time processing of weld seam information to guide industrial robots or welding special machines to autonomously correct the programmed path to meet intelligent production requirements.

The laser seam tracking sensor mainly consists of CMOS camera, semiconductor laser, laser protection lens, anti-spatter baffle and air-cooling device. Adopting the laser triangle reflection type principle, that is, the laser beam is focused and shaped and projected onto the surface of the object to be measured, the diffuse reflected light is imaged on the COMS sensor through the high quality optical system, and this image information is processed to generate the working distance, position, shape and other information of the object to be measured, and the deviation of the robot programming path is calculated and corrected through the analysis and processing of the detection data. The obtained information can be used for seam search and positioning, seam tracking, adaptive welding parameter control and transferring the information to the robot cell in real time to complete various complex welds, avoid welding quality deviations and realize intelligent welding.

Role of laser seam tracking system

Manual or semi-automatic welding relies on the operator's naked eye observation and manual adjustment to achieve the tracking of the weld seam.

For fully automated welding applications such as robots or automatic welding special machines, the main reliance is on the reproduction of the machine's teachings, the accuracy and consistency of the workpiece and its assembly to ensure that the welding gun can be aligned with the weld seam within the accuracy permitted by the process. Once the accuracy does not meet the requirements, the robot needs to be re-trained.

The sensor is usually mounted in front of the gun at a predetermined distance (ahead), so it can observe and measure the weld seam in advance and calculate the position of the weld seam in relation to the gun

By calculating the deviation between the detected weld seam and the welding gun, the device outputs the deviation data, and the motion actuator corrects the deviation in real time to precisely guide the welding gun to weld automatically, thus realizing real-time communication with the robot control system to track the weld seam for welding, which is equivalent to putting eyes on the robot.

The value of laser seam tracking system welding

Usually, the machine's repetitive positioning accuracy and demonstration reproduction function are already sufficient to meet the requirements of welding.

However, in many cases, the accuracy and consistency of the workpiece and its assembly do not easily meet the requirements of large workpieces or high-volume automatic welding production, where there are also the effects of stress and deformation due to overheating. Therefore, once these situations are encountered, there is a need for automatic tracking devices that are used to perform functions similar to the coordinated tracking and adjustment of the human eye and hand in manual welding. Improving the labor intensity of manual work helps companies to reduce production costs and improve operational efficiency.

One of the main research directions of welding technology in the future is the characteristics of weld tracking technology(2023年)

Intelligentlaser — 2023-09-08T15:45:48+0900

https://www.intelligent-laser.com/one-of-the-main-research-directions-of-welding-technology-in-the-future-is-the-characteristics-of-weld-tracking-technology.html

The world's major industrialized countries attach great importance to the role of welding research institutions, basically the formation of universities, research institutes, enterprises, three-tier research and development system. The major industrial countries have set up welding research institutes, such as the British Welding Institute (TWI), the United States Edison Welding Institute (EWI), the French Welding Institute (FWI), Japan's connection and dissolution Institute (JRWI), Ukraine's Patton Electric Welding Institute (PEWI). They all belong to national welding research institutes.

Weld tracking technology, one of the main research directions for future welding technology

Sensor technology offers many possibilities for welding operations. Some are inexpensive and have limited functionality, while others require significant investment and thoughtful design - its greatest benefit is the cost savings in use. On balance, laser seam tracking system technology is the best seam tracking solution available.

The laser seam tracking system, consisting of a laser sensor and a control unit, uses optical propagation and imaging principles to obtain information about the position of each point in the laser scanning area and to complete online real-time inspection of common weld seams through complex programming algorithms. There are corresponding function settings for detection range, detection capability and for common problems in the welding process. The device calculates the deviation between the detected weld seam and the welding gun, outputs the deviation data, and the motion actuator corrects the deviation in real time to precisely guide the welding gun to automatically weld, thus realizing intelligent real-time tracking of the weld seam in the welding process.

Advantages of optical weld seam tracking

1. Ensures safe welding and perfect welds

2. Reduces heat load

3. Increases productivity

4. Enables the welding gun to be in the ideal position

5. Compensates for production, equipment and operating tolerances

6. Reduces programming effort for complex welds

7. Enables consistent and reproducible welds

Visual seam tracking versus arc seam tracking

With the exception of arc tracking, any seam tracking welding solution for the welding process will add cycle time, but laser seam tracking will add minimal time, typically about a quarter of a second per scan, which is negligible except for position finding applications. Optical seam tracking can reach as fast as 12 meters per minute, so it does not limit the speed of the robot or gantry if high travel speeds are required. Laser robotic seam tracking can also be used for processes other than welding, such as cutting, gluing and grinding.

Laser tracking has particular advantages over arc tracking because it does allow the machine to run over the part or offline. Material inconsistencies such as rust, scale, etc. have little to no effect on laser weld tracking because tracking is based entirely on the imaging of the part.

If you want to know more kinds of laser vision system, please visit our website.

One of the main research directions of future welding technology: weld tracking technology(2023年)

Intelligentlaser — 2023-09-08T15:45:07+0900

https://www.intelligent-laser.com/seam-tracking-system-intelligent-solutions/

Weld tracking technology, one of the main research directions for future welding technology

Sensor technology offers many possibilities for welding operations. Some are inexpensive and have limited functionality, while others require significant investment and thoughtful design - its greatest benefit is the cost savings in use. Laser seam tracking vision in welding technology is the best seam tracking solution available.

The laser seam tracking welding system, consisting of a laser sensor and a control unit, uses the optical propagation and imaging principle to obtain information about the position of each point in the laser scanning area and to complete the online real-time inspection of common weld seams through complex programming algorithms. There are corresponding function settings for detection range, detection capability and for common problems in the welding process. The device calculates the deviation between the detected weld seam and the welding gun, outputs the deviation data, and the motion actuator corrects the deviation in real time to precisely guide the welding gun to automatically weld, thus realizing intelligent real-time tracking of the weld seam in the welding process.

Advantages of optical seam tracking

- Ensures safe welding and perfect welds

- Reduces heat load

- Increases productivity

- Enables ideal torch position

- Compensates for production, equipment and operating tolerances

- Reduces programming effort for complex welds

- Enables consistent and reproducible connections

Visual weld seam tracking vs. arc tracking

Any seam tracking system welding solution for the welding process will add cycle time, but laser seam tracking will add the least amount of time, typically about a quarter of a second per scan. Optical robotic seam tracking can reach as fast as 10 meters per minute, so it does not limit the speed of the robot or gantry if high travel speeds are required. Laser seam tracking can also be used for processes other than welding, such as cutting, gluing and grinding.

Principle and Advantages of Laser Vision Seam Tracking System(2023年)

Intelligentlaser — 2023-09-08T15:44:09+0900

https://www.intelligent-laser.com/products/

The laser vision system sensor scans the weld seam through laser stripes to obtain the cross-sectional area of the weld seam, the gap of the weld seam, and the height of the left and right edges of the weld seam. It is equipped with an advanced robot interface to transmit data to the robot. The robot can adjust the welding swing, swing frequency, swing left and right dwell time, welding speed, welding current and voltage in real time according to the weld seam section parameters scanned by the laser tracking vision sensor, so as to achieve high-speed, high-quality adaptive welding.

Ⅰ. The principle of laser seam tracking system

The laser tracking robot adaptive welding system is mainly composed of five parts: robot, operating device, detection head, detection head processor, and computer.

The laser seam tracking sensor adopts the principle of laser triangular reflection, that is, the laser beam is amplified to form a laser line, which is projected onto the surface of the measured object. The reflected light is projected onto the imaging matrix through a high-quality optical system. Distance (Z-axis) and positional information along the laser line (X-axis) of the measured surface. By moving the object under test or the probe of the profiler, a set of three-dimensional measurements can be obtained. The obtained information can be used for seam search and positioning, seam tracking, adaptive welding parameter control, seam shape detection, and real-time transmission of information to the manipulator unit to complete various complex welding, avoid welding quality deviation, and realize intelligent welding.

Ⅱ. Advantages of laser seam tracking system

1. Omit a lot of manual teaching operations, making robot welding easier

For traditional welding, a lot of teaching work is required during the welding process, especially for workpieces with large deformations, which are difficult to fully automate welding. But the industrial robot seam tracking system based on the laser profile sensor solves this problem well. Personnel do not need to repeatedly teach the system to work stably.

2. It can realize the identification of various conventional welds

Using the expert recognition mode for conventional welds can locate the welding position relatively accurately, and the expansion of weld types is also relatively convenient, and the recognition method can be flexibly adjusted according to the needs of the site.

3. Facilitate the expansion of welding automation

The industrial robot seam tracking system based on the laser vision seam tracking sensor can not only guide accurate welding in the welding process, but also have a certain space for the quality inspection of the seam after welding.

If you want to know more about robot vision system applications, please visit our website.

Now the price of sensors and vision system in robotics is reasonable, if you have needs, please contact us.

How to Realize Seam Tracking and Positioning?(2023年)

Intelligentlaser — 2023-09-08T15:41:56+0900

https://www.intelligent-laser.com/seam-tracking-system-intelligent-solutions/

With the development of science and technology, more and more welding robots have gradually replaced manual welding, but welding robots can only perform high-repetition batch welding work, and cannot think about how to weld highly complex workpieces like humans.

However, it is undeniable that welding robots have been incorporated into daily production by more and more small and medium-sized enterprises due to their high efficiency, high quality, simplicity and convenience. However, for some welding seam work that requires relatively high precision, it cannot be perfectly handled by welding robots alone. At this time, we need to add a laser seam tracking system.

Ⅰ. Why does the current robot welding need to install a welding seam tracking system?

1. The actual production status of the user: There are many types of welding products, small batches, and high requirements for welding precision and welding technicians.

2. The cost of workpiece feed improvement is high: update the processing equipment of the original process, design and purchase of high-precision tooling.

3. Welding robots often encounter various technical conditions such as workpiece clamping deviation and sheet metal thermal deformation during the welding production process.

4. Welding robots often need manual repair welding after welding. For small and medium-sized enterprises, it not only increases labor costs, but also increases the repair rate of products.

In order to improve the processing efficiency of the welding robot and reduce the teaching time and difficulty, it is very necessary to match the laser seam welding tracking system in time.

Ⅱ. How to realize automatic seam tracking and positioning?

The common method to realize the seam tracking and positioning of welding robots is peripheral auxiliary detection, which mainly realizes laser tracking and photographic imaging tracking. This welding seam tracking and positioning control system can collect data related to the welding seam through optical measurement equipment, and the welding robot can adjust the motion trajectory of the adaptive arm through data comparison, thereby realizing real-time tracking of the welding seam.

The laser seam tracking system of the welding robot detects and calculates the offset of the seam by laser scanning the seam before welding, processes the collected seam parameter information through the sensor, controls the robot to correct the deviation of the seam, and replans the welding trajectory, which enables seam tracking.

The trend of industrial intelligence is irreversible. With the development of the economy, robot welding will gradually replace manual welding. Although it is difficult to completely replace it, in actual welding applications, it is still possible to replace 90% of repetitive batch welding work. We have learned that welding robots have higher efficiency, guaranteed welding quality, and no emotional problems to facilitate management. This makes enterprises love it. However, for many welding workpieces that require high precision, robots themselves are not competent. At this time, a laser seam tracking system must be used to assist.

Welding Seam Tracking Technology, the Critical Eye-of Industrial Robots(2023年)

Intelligentlaser — 2023-09-08T15:41:10+0900

https://www.intelligent-laser.com/

The robot market has mushroomed and is becoming the new engine of global manufacturing industry. Behind the sweeping of intelligent manufacturing around the world, the machine vision technology, which is called the "sharp-eyed" role of industrial robots, has contributed a lot! Laser seam tracking system is an important equipment for intelligent welding robot.

Principle of laser welding robotic seam tracking system

Vision system, combined with intelligent laser and vision technology, can realize the accurate detection of three-dimensional coordinates, and make the robot realize the functions of self-recognition and self-adjustment. It is the core component of robot control. The system is mainly composed of two parts: laser sensor and control host. The laser sensor is responsible for the active acquisition of weld information, and the control host is responsible for the real-time processing of weld information. It guides industrial robots or special welding machines to modify programming paths independently to meet the demand of intelligent production.

The laser seam tracking sensor is mainly composed of CMOS camera, semiconductor laser, laser protection lens, splash guard and air cooling device. The principle of laser triangular reflection is adopted, that is, the robot laser beam is focused and shaped, and then projected on the surface of the measured object. The diffuse reflection light passes through a high-quality optical system and is imaged on a COMS sensor. After these image information is processed, the working distance, position, shape and other information of the measured object can be generated. By analyzing and processing the detection data, the deviation of the robot programming trajectory can be calculated and corrected. The obtained information can be used for welding seam search and positioning, welding seam tracking, adaptive welding parameter control, and the information can be transmitted to the manipulator unit in real time to complete all kinds of complicated welding, avoid welding quality deviation and realize intelligent welding.

Role of laser welding seam tracking system

Manual or semi-automatic welding relies on operator's naked eye observation and manual adjustment to realize the tracking of welding seam.

For fully automatic welding applications, such as robots or automatic welding machines, the teaching and reproduction of machines, the accuracy and consistency of workpieces and their assembly are mainly relied on to ensure that the welding gun can align the welding seam within the precision range permitted by the process. Once the accuracy can't meet the requirements, the robot needs to be re-taught.

The sensor is usually installed at the front of the welding torch at a preset distance (ahead), so it can observe and measure the collective information of the welding seam in advance, and calculate the positional relationship between the welding seam and the welding torch.

By calculating the deviation between the detected weld and the welding torch, the equipment outputs deviation data, and the motion actuator corrects the deviation in real time, and accurately guides the welding torch to weld automatically, thus realizing real-time communication with the robot control system to track the weld seam for welding, which is equivalent to putting eyes on the robot.

Value of laser welding seam tracking system

Usually, the repetitive positioning accuracy, teaching and reproduction function of the machine can meet the requirements of welding

However, in many cases, the accuracy and consistency of workpiece and its assembly are not easy to meet the requirements of large-scale workpiece or mass automatic welding production, and there is also the influence of stress and deformation caused by overheating. Therefore, once these situations are encountered, it is necessary to have an automatic tracking device, which is used to perform a function similar to the coordinated tracking and adjustment of human eyes and hands in manual welding. Improve the labor intensity of manual operation, help enterprises reduce production costs and improve operation efficiency.

The Development of Welding Seam Tracking Technology(2023年08月14日)

Intelligentlaser — 2023-08-08T17:36:53+0900

https://www.intelligent-laser.com/seam-tracking-system-intelligent-solutions/

Development course of welding seam tracking technology

A key technology of intelligent welding is to realize automatic positioning and real-time tracking of workpieces and welds. In the early days, due to the backwardness of basic technologies related to detection and computer, it was difficult to realize the technology of welding seam positioning and tracking. The factory usually only designed and produced precise fixtures, and at the same time, it raised the requirements for assembly. However, for small batch production, this method was usually difficult to realize.

Conclusion of welding seam tracking technology

Compared with other welding seam tracking technologies, the welding seam positioning and real-time tracking technology based on laser structured light has wider application scenarios and higher real-time and accuracy. In the future, welding seam tracking based on laser, especially 3D imaging technology, is bound to have a broader development in the field of intelligent welding.

Intelligent Laser provides robot machine vision, laser seam tracking welding, laser welding robot system, robotic welding system, robotic vision, etc. For laser tracking cost or more information, please feel free to contact us!

Fusion and Application of Welding Seam Tracking Technology and New Technology(2023年08月13日)

Intelligentlaser — 2023-08-08T17:35:43+0900

https://www.intelligent-laser.com/seam-tracking-system-intelligent-solutions/

In recent years, with the development of off-line programming technology, communication technology, virtual reality and artificial intelligence, vision-based seam tracking technology is also developing. The fusion of welding seam tracking technology and new technology makes automatic welding technology get new development!

1.The combination of offline programming technology and automatic welding seam tracking technology.

Off-line programming technology is based on computer graphics and robot kinematics and other technologies to simulate the robot's actions, and to generate the robot's trajectory and corresponding robot operations through graphic programming. Compared with the traditional staff who teach programming through robot teaching device, off-line programming can greatly improve work efficiency, and at the same time, it can keep programmers away from harsh or dangerous working environment. In recent years, off-line programming technology is developing towards the direction of full automation and even more intelligence. The combination of off-line programming technology and automatic welding seam tracking technology can play a part of teaching-free role, which can greatly reduce the workload in the case of a large number of welding seams with various forms.

2. Welding remote control technology.

Remote control welding means that the operator is far away from toxic, deep water, nuclear radiation, inflammable and explosive dangerous working environment, and realizes remote control of welding equipment and welding process. At present, intelligent welding technology can't be fully realized in the field of welding, so it is necessary to use remote control to remotely control the welding equipment to ensure the accuracy and quality of welding. As early as 1970s, operators had already finished welding by controlling the movement of welding gun through remote operation of actuator. In the mid-1980s, remote control welding technology using robots was studied abroad. The earliest application was in Douglas Point nuclear power station in Canada in 1984, and the reactor leakage accident was successfully repaired by remote control welding. Active vision sensing is the main sensing method used in remote welding. With the development of welding pool monitoring camera, there are more and more environments and parameters that can be remotely controlled.

3.3D scanning imaging and artificial intelligence technology.

The robot autonomous welding system based on 3D vision can quickly and independently generate the weld trajectory based on the point cloud image generated by structured light camera and artificial intelligence, and then generate the robot's laser locating, idling and welding trajectory based on the weld trajectory, and add the welding process on the basis of expert database. The system does not need to input an accurate 3D digital model, teaching and programming. After 3D scanning the workpiece, the robot welding trajectory is generated independently, and the laser precise positioning and rectification work is combined together, so it is very suitable for solving the common independent welding of many varieties and small batches of products in industrial field. This kind of welding system can effectively improve the overall welding quality and efficiency by omitting the steps of creating the workpiece model, off-line programming and robot teaching.

Intelligent Laser provides robotic vision, seam tracking system welding, robot welding seam tracking, robot welding laser seam tracking, robotic vision, etc. For laser tracking cost or more information, please feel free to contact us!

The Characteristics of Welding Seam Tracking Technology(2023年08月12日)

Intelligentlaser — 2023-08-08T17:34:57+0900

https://www.intelligent-laser.com/seam-tracking-system-intelligent-solutions/

All major industrial developed countries in the world attach great importance to the role of welding research institutions, basically forming a three-level research and development system of universities, research institutes and enterprises. Major industrial developed countries have set up welding research institutes, such as TWI in Britain, EWI in America, FWI in France, JRWI in Japan and PEWI in Ukraine. They all belong to national welding research institutions.

Welding seam tracking technology is one of the main research directions of welding technology in the future.

Sensor technology provides many possibilities for welding operation. Some have low cost and limited functions, while others require a lot of investment and thoughtful design-its greatest advantage is that it saves the cost in use. On the whole, laser vision welding seam tracking technology is the best welding seam tracking solution at present.

The laser seam tracking system is mainly composed of a laser sensor and a control host. By using the principle of optical propagation and imaging, the position information of each point in the laser scanning area can be obtained, and the online real-time detection of common welds can be completed through complex program algorithms. There are corresponding function settings for the detection range, detection ability and common problems in the welding process. By calculating the deviation between the detected weld and the welding torch, the equipment outputs deviation data, and the motion actuator corrects the deviation in real time, and accurately guides the welding torch to weld automatically, thus realizing the intelligent real-time tracking of the weld in the welding process.

Advantages of optical seam tracking

1. Ensure safe welding and perfect welding seam.

2. Reduce the heat load

3. Improve productivity

4. The welding gun can be in an ideal position.

5. Can compensate the tolerance of production, equipment and operation.

6. For complex weldments, the programming work can be reduced.

7. Consistent and reproducible welding can be achieved.

Comparison between Visual Weld Tracking and Arc Weld Tracking

Except arc tracking, any welding seam tracking solution for the welding process will increase the cycle time, but laser welding seam tracking will increase the minimum time. Usually, the welding seam cycle of each scan is about a quarter of a second, and the increased time can be neglected except for position finding applications. Optical seam tracking can reach 12m per minute at the fastest, so it will not limit the speed of robot or gantry if high traveling speed is required. Laser seam tracking can also be used for processes other than welding, such as cutting, gluing and grinding.

Compared with arc tracking, laser tracking has special advantages, because it does allow equipment to run over parts or off-line. Material inconsistency, such as rust and scale, has little effect on laser welding seam tracking, because tracking is completely based on the imaging of parts.

Seam Tracking System in Medium and Heavy Plate Cutting(2023年08月11日)

Intelligentlaser — 2023-08-08T17:34:01+0900

https://www.intelligent-laser.com/laser-seam-tracking-system-cases/

Based on visual inspection technology, Intelligentlaser has developed a visual seam tracking + parametric programming solution for medium and heavy plate. The intelligent welding solution for medium and heavy plate is composed of a laser sensor, a host control unit, a CUTEWELDER software system. After configuration, the laser seam sensor is able to pre-scan the workpiece and then form a profile of the workpiece feature points. Users can make a plan of the robot path on the basis of the feature points. Therefore, they can realize many welding processes, like reciprocating welding and intermittent welding, to improve efficiency.

Seam Tracking System in Friction Stir Welding(2023年08月10日)

Intelligentlaser — 2023-08-08T17:33:14+0900

https://www.intelligent-laser.com/

Based on visual inspection technology, Intelligentlaser has developed a complete seam tracking solution for stir friction welding. The sensor can acquire an accurate position by scanning and then guide the robot to weld. In the meanwhile, the system can work with the movement of the mixing head, which realize the visual sensing in Y direction and pressure sensing in Z direction. It is very flexible because it can weld for 1D, 2D and 3D structure. Also, it can weld the seam without burrs which not only lower the cost efficient but also save the labor from polishing.

Intelligent Laser provides seam tracking sensor, robotic vision systems, robot vision system, robotic vision, laser vision system, etc. For more information, please feel free to contact us!

Seam Tracking System in Aluminum Alloy Tank Welding(2023年08月09日)

Intelligentlaser — 2023-08-08T17:32:28+0900

https://www.intelligent-laser.com/

Based on visual inspection technology, Intelligentlaser has developed a visual seam tracking + parametric programming solution for aluminum alloy tank. The intelligent welding solution for aluminum alloy tank is composed of a laser sensor, a host control unit, a CUTEWELDER software system. With our solution, the user just needs to enter the feature parameters of the workpiece. In the meantime, the image algorithm inside the CUTEWELDER software system can also shield the interference of the joints, arc and spatter. The accuracy of the tracking weld can reach +-0.1mm. Moreover, the solution can be used for high-reflective workpiece such as stainless steel, aluminum alloy and polished metal, etc.

Intelligent Laser provides seam tracker, laser vision system, laser seam tracking, robot machine vision, robotic seam tracking, etc. For more information, please feel free to contact us!

Seam Tracking System in Shrimp Waist Welding(2023年08月08日)

Intelligentlaser — 2023-08-08T17:31:22+0900

https://www.intelligent-laser.com/

Based on visual inspection technology, Intelligentlaser has developed a visual seam tracking + parametric programming solution for shrimp waist circular weld. The intelligent welding solution for shrimp waist is composed of a laser sensor, a host control unit, a CUTEWELDER software system. With our solution, the user just needs to enter the feature parameters of the workpiece. In the meantime, the image algorithm inside the CUTEWELDER software system can also shield the interference of the joints, adjust the welding process automatically. Therefore, our solution can help weld accurately even the torch is changing all the time. This intelligent solution supports many tracking ways, such as laser tracking. The accuracy of the tracking weld can reach +-0.1mm. Moreover, the solution can be used for high-reflective workpiece such as stainless steel, aluminum alloy and polished metal, etc.

Intelligent Laser provides laser brazing machine, laser seam tracking system, robotic seam tracking, intelligent laser, intelligent laser, etc. For more information, please feel free to contact us!

Basic Components and Benefits of Adding System to Robot Vision System(2023年07月05日)

Intelligentlaser — 2023-06-30T15:37:20+0900

https://www.intelligent-laser.com/

A robot machine vision system can perform continuous inspections, improving product quality, increasing yield, and reducing production costs. It ensures consistent product appearance and quality while reducing unnecessary processing steps.

Machine vision refers to the automatic visual inspection of manufactured goods using industrial cameras, lenses, and lighting. Robot vision systems provide a fast and reliable way to inspect parts online. With robotic vision systems, every part on a high-speed production line can be imaged and inspected to ensure 100% quality control.

Basic components of robot vision systems

A robot's vision system, also known as an automatic vision system or visual inspection system, consists of several components that are common to most systems.

The lighting used in a robot laser vision system should be selected to maximize the contrast of any features being measured or observed while minimizing the contrast of all other features of the part. Achieving this goal may require altering the amount of light used, the way that it is used, and the position of the light source relative to the part and optical system or camera.

Benefits of adding a robot vision system

What Are the Different Ways for Robots to Track Weld Seams?(2023年07月04日)

Intelligentlaser — 2023-06-30T15:36:24+0900

https://www.intelligent-laser.com/seam-tracking-system-intelligent-solutions/
https://www.intelligent-laser.com/

Robot welding cannot meet the actual needs of some products with lower precision, so it is necessary to add a robot welding laser seam tracking system. So what are the ways of robot welding seam tracking? Next, we will briefly introduce them.

Types of robot welding seam tracking

Robot welding laser seam tracking includes arc tracking and laser tracking. Thick plates usually use arc tracking, mainly oscillating welding. The deviation between the welding seam and the programming is calculated by contacting the two surfaces of the welding wire and the base metal, and then welding is performed by swinging. When the welding robot is used for the first time, it generally needs to be equipped with arc tracking detection function. The welding seam can be detected before welding, or the welding seam can be detected at the same time.

How does robot welding seam tracking work?

If you want to know more kinds of robotic vision systems, please visit our website.

How to Achieve Automatic Weld Seam Tracking and Localization with Welding Robots?(2023年07月03日)

Intelligentlaser — 2023-06-30T15:35:39+0900

https://www.intelligent-laser.com/seam-tracking-system-intelligent-solutions/

The importance of automatic weld seam tracking system for welding robot configuration

High cost of improving the workpiece feeding: updating the original processing equipment and designing with high-precision fixtures.

Users' actual production situation: welding products have many varieties, small batches, and high requirements for welding accuracy and welding technicians.

In order to improve the processing efficiency of welding robots, reduce teaching time and difficulty, and solve the positioning problem of automatic seam tracking welding, it is imperative.

What is automatic seam tracking and welding positioning of welding robots?

Welding positioning: The process of using one or more searches to determine the position of the weld to be welded by moving the welding robot or editing the machine program path.

How to automatic seam tracking and positioning of welding robots?

There are multiple methods for the automatic seam tracking and positioning of welding robots. The commonly used methods are peripheral auxiliary detection and self-detection.

Auxiliary detection: intelligent laser tracking and photographic imaging tracking. The seam tracking and positioning control system can collect seam-related data through optical measurement equipment, and the welding robot can adjust the adaptive arm's movement trajectory through data comparison, thereby realizing real-time seam tracking.

Self-detection: Inductively test welding wire and real-time test welding parameters.

Methods for realizing the automatic seam tracking and positioning of welding robots

The seam tracking and positioning methods of welding robots have their own advantages and disadvantages. The working principles of the following two methods are summarized:

Real-time seam detection method:

It can reduce costs: reduce the cost of detection equipment, but the cost of welding robot body and welding equipment will correspondingly increase.

There are many limitations to the applicable welding production environment.

Laser seam tracking is currently the preferred mature and reliable control method in the market

It is not limited by welding process, method, and environment.

Peripheral equipment welding robots.

Increased peripheral hardware costs.

PREV: What Are the Different Ways for Robots to Track Weld Seams?NEXT: Weld Seam Tracking Sensor Technology Introduction
Popular Seam Tracking Systems

Weld Seam Tracking Sensor Technology Introduction(2023年07月02日)

Intelligentlaser — 2023-06-30T15:34:56+0900

https://www.intelligent-laser.com/seam-tracking-system-intelligent-solutions/

The concept of welding seam tracking system
The automatic weld seam tracking sensor mainly consists of a CCD camera, a semiconductor laser, a laser protection lens, a splash-proof baffle, and a wind cooling device. By using the principle of triangulation, the coordinate information of each point in the laser scanning area is obtained, and the online real-time detection of common welding seams is realized through complex program algorithms, and the robot is guided to adjust the working trajectory according to the scanning data.

The principle of laser welding tracking system
The laser weld seam tracking system adopts a laser triangulation reflection principle, that is, the laser beam is amplified to form a laser line projected onto the surface of the object to be measured. The reflected light passes through a high-quality optical system and is projected onto the imaging matrix to obtain the distance from the sensor to the surface of the measured object (Z axis) and the orientation information along the laser line (X axis) by calculation. Moving the measured object or the contour gauge probe can obtain a set of three-dimensional measurement values.

The development and prospect of weld laser seam tracking

The weld seam tracker can be said to be a great invention for welding. With the development of technology, achieving welding automation and intelligence has become an inevitable trend.

What Are the Advantages of Robot Welding?(2023年07月01日)

Intelligentlaser — 2023-06-30T15:34:16+0900

https://www.intelligent-laser.com/seam-tracking-system-intelligent-solutions/

Many people have misunderstandings about robot welding seam tracking, thinking that it is difficult to make the leap from manual welding to automatic welding. However, in fact, robot welding laser seam tracking can be completed through simple steps.

Fortunately, we now have a very simple way to program robots and achieve perfect welding in a short time. In this article, we will introduce 5 advantages of robot welding.

High productivity of robot welding

Robots work faster than manual operations, so the production cycle of products will be shortened. And robots do not need to rest while working, so the time saved can be used to increase production, and the output of the entire production line can be increased significantly through accumulation.

High efficiency of robot laser welding

To ensure the quality of welding, manual welding points are usually larger than the welding area required by the processing technology. Unnecessary welding areas, even a little bit more than what is required by the process, can accumulate into huge costs over a long period. Studies have shown that if each weld spot is 1 millimeter wider than required, it may bring an additional $10,000/year in cost to the company.

PREV: Seam Tracking Welding Sensor Technology IntroductionNEXT: Why Weld Seam Tracking System is an Important Factor in Achieving Welding Process Automation?
Popular Seam Tracking Systems

Why Weld Seam Tracking System is an Important Factor in Achieving Welding Process Automation?(2023年)

Intelligentlaser — 2023-06-14T12:46:30+0900

https://www.intelligent-laser.com/seam-tracking-system-intelligent-solutions/

The automation robot welding has great advantages compared with traditional manual welding. With the equipment of welding automation technology, it can improve the efficiency and quality of welding processing, reduce energy and material consumption, save production costs, lighten the labor intensity of workers, improve the working environment of welding and thus enhance the image of enterprises and make enterprises more competitive in the industry.

The Characteristics of Automation Welding

Industrial laser welding robots usually adopt the working mode of "teaching and reproduction". In the process of robot welding, they can repeat the actions that have been taught with high precision in their workspace. However, this way of working also has certain limitations. The strain capacity of the robot is poor, and the assembly precision of the workpiece is strict. The consistency of the base metal should be good in order to ensure the welding quality when the welding conditions are basically stable.

But in the actual welding process, because the operator is not allowed or suitable to enter the working area of the robot in order to avoid danger during the operation of the industrial robot, the operator cannot monitor the welding process from a close distance in real time and cannot make necessary adjustment and control. Therefore, when the actual welding conditions change, such as the size error and position deviation of the workpiece in the process of processing and assembly during the welding process as well as the variation of the workpiece heating deformation and other factors, it will make the joint position deviates from the path of demonstration taught, which often leads to the decrease or even failure of welding quality. Accurate welding seam tracking is the key to ensure the welding quality, and it is an important factor to achieve welding automation.

The Function and Composition of Weld Seam Tracking System

The function of the welding seam tracking system is to automatically detect and adjust the position of the welding gun (similar to the eyes of the robot) during welding, so that the welding gun can always weld along the weld seam and keep the distance between the gun and the workpiece constant, thus ensuring the welding quality, improving the welding efficiency and reducing the labor intensity.

The standard weld seam tracking system mainly consists of three parts: the executive mechanism (industrial robots, welding special machines, etc.), the weld seam tracking sensor, and the control system. The sensor is used for real-time collection of weld seam information, and the control system receives the signal from the sensor, and then adjusts the position of the welding gun through the feedback of the executive mechanism to achieve weld seam automatic tracking.

The Function and Composition of Weld Seam Tracking System

The common weld seam tracking sensors can be divided into: contact sensors, ultrasonic sensors, infrared sensors, arc sensors, and laser vision sensors based on their working principles.

Contact Sensors

Contact sensors usually use probes to contact with the side wall of the workpiece or a side wall of the weld seam in front of the welding gun. By detecting the offset of the probe, the control system can track the position of the weld seam. Its advantages are that it is not affected by arc interference and has low cost. However, the tracking accuracy is not high, the probe is prone to wear and deformation, and it is not suitable for tracking complex groove welds or high-speed welding, and has gradually been replaced by other sensing methods.

Ultrasonic Sensors

Ultrasonic sensors detect the information and geometric shape of the weld seam by judging the time of the echo. It is not easily affected by electromagnetic, light, smoke and other interference during welding. However, it needs to be close to the workpiece, and is sensitive to noise, so it is easily affected by noise interference. For example, its application in CO2 gas shielded welding has certain limitations.

Arc Sensor

Arc sensor calculates the shape information of the weld groove by utilizing the movement of the arc relative to the weld seam, and calculates the distance change between the welding gun and the workpiece through the parameter changes of arc voltage and current, so as to achieve the tracking control of the welding gun in the two directions of high and low and left and right. The arc sensor uses the arc itself as a sensor. Its advantages are the arc interference, magnetic field, splashing, smoke and other interference. Its disadvantage is the strong dependence on the groove shape, poor recognition ability for joints with asymmetrical side walls or no side walls at all, and cannot achieve automatic detection of the start and end points of welding.

Laser Vision Sensor

Laser vision sensor is considered to be the most promising weld seam tracking sensor. Based on the principle of triangulation, the laser projects the line-structure light onto the object to be detected through the lens group, which receives the diffuse reflection on the object and forms images on the CMOS/CCD sensor through the receiving lens group. These image data can be processed to generate information such as working distance, position and shape of the measured object. The control system analyzes and processes the monitoring data through special algorithms, and calculates and corrects the deviation of the welding robot/special machine welding trajectory to achieve weld seam tracking.

Through the laser vision sensor, not only can the information of the weld seam be obtained, but also the width of the molten pool after welding can be observed. The laser vision sensor is increasingly valued for its high sensitivity, high precision, anti-electromagnetic interference, no contact with the workpiece, and rich information about weld seam. And it has become the mainstream product of weld seam tracking sensor.

More kinds of robot vision system, please visit our website.

Composition and Function of Weld Seam Tracking Sensor(2023年)

Intelligentlaser — 2023-06-14T12:45:55+0900

https://www.intelligent-laser.com/seam-tracking-system-intelligent-solutions/
https://www.intelligent-laser.com/

The CMOS camera of the weld seam tracking sensor

The main function of the CMOS camera in the robot welding seam tracking sensor is to read the image. The CMOS control chip controls the current generated by the photodiode through the control signal line in the photosensitive element, and outputs it through the current transmission circuit. The CMOS camera collects the electrical signals generated by a single imaging, and outputs them uniformly to the amplifier. The electrical signals, amplified and filtered, are sent to the A/D converter, where the analog signals are converted into digital signals, with the size of the values being proportional to the strength, intensity and voltage of the electrical signals. These values are actually the data of the image.

However, only relying on the image data obtained from the previous step cannot directly generate images, and they need to be output to the digital signal processor (DSP). In the DSP, these image data are processed in post-processing such as color correction and white balance adjustment.

The semiconductor laser of the weld laser seam tracking sensor

A laser source that generates power through a linear generator, featuring uniform density, high straightness, good stability, and outputting in a straight line. The laser has both red and blue options and can choose the appropriate wavelength angle and linewidth according to specific customer requirements.

The filter protection lens of the weld seam tracking sensor

Since the smoke and splashes generated during the welding process will have a certain influence on data collection, each sensor must be equipped with a filter protection lens, which is used for protecting the laser and camera, and can also filter the light.

When there is dirt on the surface, it must be replaced in time. During the installation and replacement of the protective lens, any adhesive or even fingerprints or oil droplets will increase the absorption rate of the lens, reducing its service life, so cleaning the lens cannot be ignored.

The anti-splash baffle of the weld seam tracking sensor

Mainly used to block the interference of arc light, splashes, and smoke on the laser, so that the sensor system is more accurate and stable when in use.

The air-cooled device of the weld seam tracking sensor

Due to the high temperature during welding, most devices now use air cooling systems, which are used for cooling the sensor and extending the service life of the weld seam tracking sensor.

The protection level of the sensor's casing is IP67, and it is suitable for use at temperatures between 5℃ - 45℃. If necessary, an additional water-cooled mounting plate can be used to cool the sensing head.

The sensor completes the online real-time detection of common weld seams through a complex program algorithm. There are corresponding functional settings for the detection range, detection ability and common problems in the welding process. The equipment calculates the deviation data between the detected weld seam and the welding gun, and outputs the deviation data. The motion executing mechanism corrects the deviation in real time and accurately guides the welding gun for automatic welding, thus achieving intelligent real-time tracking of the weld seam in the welding process.

The company was founded with the introduction of the technology from Tsinghua University. Since, we have begun the research of robot laser seam tracking system.

Is It Necessary to Install a Seam Tracking System for Welding Robots?(2023年)

Intelligentlaser — 2023-06-14T12:45:12+0900

https://www.intelligent-laser.com/seam-tracking-system-intelligent-solutions/

With the popularization of automation technology, industrial robots are increasingly applied in enterprises, among which welding, as the main application of industrial robots, accounts for more than 50% in the market. Many enterprises will install automatic weld seam tracking systems on robots to improve welding efficiency. However, many friends who are new to welding robots do not know the role of seam tracking welding systems and why they need to be installed.

Today, let's learn about the role of laser seam tracking welding systems together.

Teaching and Reproduction

Before studying the role of welding robotic seam tracking systems, we need to first understand the basic working principle of industrial robots, "teaching and reproduction". Teaching, also known as guidance, is guided by the user to guide the robot to perform the actual task step by step. During the guidance process, the robot automatically remembers the position, attitude, motion parameters, process parameters, etc. of each action in teaching and generates a program that executes all operations continuously. After completing the teaching, just give the robot a start command, and the robot will perform all operations accurately in accordance with the teaching actions, step by step. This is teaching and reproduction. Simply put, tell the robot where the starting point and end point of the workpiece to be welded are, so that the welding trajectory can be generated based on the teaching points to carry out the work.

However, this trajectory is fixed. If in real production, the workpiece deviates due to pairing, placement, or clamping, and the actual position of the workpiece is inconsistent with the teaching position, the robot is not aware of it and will still weld according to the teaching trajectory, which will cause problems such as miswelding and leakage welding, seriously affecting welding quality and production efficiency.

Welding Seam Tracking System

After the welding robot is equipped with a welding seam tracking system, the laser vision system installed at the front end of the robot welding gun can actively collect welding seam information through optical measurement algorithms, complete information processing quickly through the control host, and feedback to the robot or welding specialized machine to autonomously correct the teaching trajectory, realizing real-time tracking of the welding seam and achieving high-quality welding. It is equivalent to giving the robot "eyes" to "see" the welding seam.

Can effectively solve the following pain points:

● Poor consistency of workpiece welding seams, requiring repeated teaching

● Need to strictly control the processing accuracy of the previous process

● Welding process requires the use of large and complex fixtures for positioning

● Workpieces deform due to heat

The laser vision welding seam tracking system, as an important component of the welding automation control system, can guide the robot to identify welding seam information, correct deviation, teach a single time for the same workpiece and achieve continuous production, improve welding quality, and improve production efficiency. It has become one of the core components of automatic welding.

Application of Laser Seam Tracking System in Laser Welding(2023年)

Intelligentlaser — 2023-06-14T12:44:35+0900

https://www.intelligent-laser.com/seam-tracking-system-intelligent-solutions/
https://www.intelligent-laser.com/

Stainless steel is a material commonly used in daily life. With the growth of living standards and market demand, the consumption of stainless steel has been increasing rapidly. Therefore, various products urgently need stainless steel as raw materials. In daily life, thin-walled stainless steel sheets have become widely used materials in production and manufacturing, and the quality requirements for the welding of thin-walled stainless steel sheets are also increasing.

Difficulties in welding thin stainless steel plates

As we all know, due to its small thermal conductivity, about only one-third of ordinary low-carbon steel, and small constraint, thin stainless steel sheets will form uneven stress and strain once the local area is affected by heating and cooling during the welding process. The longitudinal shrinkage of the welded seam will produce certain pressure on the outer edge of the thin stainless steel sheet, which will cause wave-like deformation of the workpiece once the pressure is too large. This not only affects the aesthetics but also affects the quality of the workpiece. In addition, burn-through and over-burning problems may also occur.

(Traditional welding process for thin plates is prone to deformation and burn-through)

The use of robots equipped with robot laser welding machine can solve the above problems of welding thin stainless steel plates. Its welding thickness is small, which can achieve 0.1 MM. The laser point is small and the heat energy is distributed evenly, with high energy. The heating range of the thin plate is small, almost achieving instant melting and welding. Moreover, all performance parameters can be set and adjusted to meet specific welding requirements of the material.

What to do with "blind welding" of laser welding?

The laser welding robot is good, but this cannot meet the production requirements. In actual production, due to the existence of errors in loading and clamping, and stress deformation, the welding robot working in the teaching mode cannot detect these error changes and will still weld according to the preset path, which will cause welding deviation, waste, and even equipment damage.

Intelligentlaser independently develops and produces laser robotic vision seam tracking system, which is equivalent to installing "eyes" on the robot. It can quickly and effectively detect the deviation between the actual seam and the teaching seam, and control the robot to weld according to the actual seam, effectively solving the above problems.

The Intelligentlaser vision sensor, paired with an ABB robot, is used for thin plate laser welding.

The laser vision seam tracking system from Intelligentlaser has the following advantages:

Rich variety of products that can meet the needs of various industries

Currently available on the market are various series and models of laser seam tracking systems, including the IL-HSP series, IL-SPD series, IL-SMT, and IL-WFV series sensors, which can be used in the automotive and shipbuilding, steel structure, pipeline, pressure vessel, container, new energy, aerospace, and military industries.

Convenient operation

The control software uses the JOB system, which can effectively manage different welding seam settings and retain the detection parameters for each work condition. The JOB system supports the simultaneous existence of 30 sets of welding seam detection parameters and updates welding detection parameters in real-time according to the robot welding process, making the operation flexible and convenient.

The Intelligentlaser laser vision system has passed CE certification, and the laser sensor has an IP65 protection level (customizable to IP67), making it better able to cope with challenges in the customer's actual on-site environment. At the same time, Intelligentlaser has a high-standard production system for vision seam tracking systems, certified by the ISO quality management system, and equipped with a strong delivery and after-sales service system to ensure worry-free project delivery.

Fusion and application of weld tracking technology and new technology(2023年)

Intelligentlaser — 2023-06-14T12:43:54+0900

https://www.intelligent-laser.com/seam-tracking-system-intelligent-solutions/

With the development of offline programming technology, communication technology, virtual reality and artificial intelligence in recent years, vision-based seam tracking system welding technology is also developing and progressing. The integration of robot welding seam tracking technology with new technologies allows for new developments in automated welding technology!

1. Offline programming technology combined with automatic seam tracking welding technology.
Offline programming technology is based on computer graphics and robot kinematics and other technologies to simulate the action of the simulation robot, and generate the robot's motion trajectory and the corresponding robot operation through image-based programming. Compared to traditional programming by staff through robot demonstrators, offline programming can greatly improve work efficiency while keeping the programmer away from harsh or dangerous working environments. In recent years, offline programming technology is developing towards fully automatic, or even more intelligent, offline programming technology combined with automatic weld seam tracking technology can play a part of the role of non-teaching, for the number of welding seams, and the form of change can largely reduce the workload.

2. Welding remote control technology.

Remote control welding refers to the operator away from toxic, deep water, nuclear radiation and flammable and explosive and other dangerous working environment, to achieve remote control of the welding equipment and welding process. Because at present in the field of welding can not fully realize the intelligent welding technology to carry out independent welding, so the need to use remote control remote control of welding equipment to ensure the accuracy and quality of welding. As early as the 1970s, the operator has already completed the welding by remotely operating the actuator to control the movement of the welding gun; the mid-1980s, the application of robotics remote control welding technology research abroad, the earliest application was achieved in 1984 Douglas Point nuclear power plant in Canada, the use of remote control welding successfully repaired the reactor leakage accident. Active visual sensing is the main application of remote control welding sensing methods, with the development of the melt pool monitoring camera, the remote control of the environment and more and more parameters.

3.3D scanning imaging and artificial intelligence technology.

3D vision-based robot welding system can be based on structured light camera generated point cloud images and based on artificial intelligence to quickly and independently generate weld trajectory, and then based on the weld trajectory to generate the robot's laser seeking, empty walk and welding trajectory, based on the expert library to add the welding process. The system does not need to input accurate 3D models, no need to teach programming, after the workpiece is scanned in 3D, the robot welding trajectory is generated autonomously, and the work of laser precise position finding and deflection correction is combined together, which is very suitable for solving the common multi-species and small batch product welding in industrial sites autonomously. This type of welding system can effectively improve the overall welding quality and efficiency by eliminating the need for workpiece pattern creation, offline programming, and robot teaching.

More kinds of robotic vision systems, please visit our website.

From contact type to non-contact type -- the development of inventory weld tracking technology(2023年)

Intelligentlaser — 2023-06-14T12:43:16+0900

https://www.intelligent-laser.com/seam-tracking-system-intelligent-solutions/

In the current welding production process, different products usually require specific welding equipment and fixtures, the need to design different types of production lines and production processes, even for similar products, due to different models, usually need to replace the fixture. At the same time, because the workpiece in the grouping process there are grouping errors, machining process there are processing errors, so it will lead to the actual welded workpiece and the design of the difference between the workpiece consistency is poor, for robot welding simple teaching usually has a large error. The thermal deformation during the welding process can also cause errors, resulting in welding defects. The above problems are common in general industrial production, which requires welding automation production lines with the ability to accurately locate the workpiece and correct deviations, as well as the ability to detect the weld seam in real time during the welding process, adjust the welding path, correct welding deviations, and ensure the quality of the weld, which can also significantly reduce the workload of the operator, improve welding efficiency, reduce manufacturing costs, and achieve intelligent and flexible manufacturing.

The development history of welding tracking system technology

A key technology for intelligent welding is to achieve automatic positioning and real-time tracking of the workpiece and weld seam. In the early days, due to the backwardness of detection and computer-related basic technology, weld seam positioning and tracking technology was difficult to achieve, and factories usually could only design and produce precision fixtures, while increasing the requirements for the assembly process, but for small batch production, this approach was usually difficult to achieve.

Since the 1970s, there has been some development in weld seam positioning and inspection technology. There are two main advances, on the one hand, the development of mechanical contact profiling tracking. Mechanical profiling has wear and tear problems over time, as well as low accuracy, which is a major limitation in application and is usually used in scenarios requiring low welding accuracy. On the other hand, based on the principle of arc sensing, researchers have achieved real-time arc tracking and wire touch position finding, but arc tracking usually requires the welded workpiece to be a fillet weld and requires the use of swing welding, which also limits the use of arc tracking.

After 2000, with the development of information technology and embedded processing technology, sensor technology and image processing technology advances, foreign researchers have made great progress in the field of non-contact real-time tracking, and the formation of productization capabilities. 2010 after China's enterprises, schools and research institutions for non-contact weld tracking technology gradually carried out in-depth research and development, while with the robot With the maturity and popularity of robot applications, welding seam tracking system technology has made a breakthrough and is gradually becoming mature.

Laser structured light detection method based on the triangulation principle The method has been widely used because of its high contrast, high accuracy, real-time and non-contact characteristics. In practical use, there are various types of laser structured light, such as single-line structured light, multi-line structured light, circular and elliptical structured light, dot matrix, etc. The most widely used is single line structured light, based on the single line structured light weld tracker has a simple structure, good real-time, cost-effective features, has been maturely used in the field of weld tracking, weld position finding, etc., is also the future development direction of weld detection and tracking.

Conclusion

Laser-based structured light weld seam positioning and real-time tracking technology has a wider range of application scenarios, and higher real-time and accuracy compared with other automatic weld seam tracking technologies. The future of laser-based weld seam tracking, especially based on 3D imaging technology is bound to have a broader development in the field of intelligent welding.

Now the laser tracking cost is reasonable, if you have needs to buy laser seam tracking system, please contact us.

Weld seam tracking technology, the "eyes of the beholder" for industrial robots!(2023年05月16日)

Intelligentlaser — 2023-05-11T17:22:55+0900

https://www.intelligent-laser.com/laser-seam-tracking-system-cases/

The industrial robot market is rapidly emerging as a new engine for global manufacturing. Behind the smart manufacturing sweeping the world, the machine vision technology, known as the role of industrial robots' "golden eye", is of great merit! Laser robotic seam tracking system is an important equipment for welding robots to achieve intelligence.

Laser welding seam tracking system principle

Laser vision system, combined with laser and machine vision technology, can achieve accurate detection of three-dimensional space coordinate position, so that the robot to achieve independent identification, independent adjustment function, is the core component of the robot control. The system is mainly composed of laser sensors and control hosts. The laser sensors are responsible for active acquisition of weld seam information, and the control hosts are responsible for real-time processing of weld seam information to guide industrial robots or welding special machines to autonomously correct the programmed path to meet intelligent production requirements.

Role of laser seam tracking system

Manual or semi-automatic welding relies on the operator's naked eye observation and manual adjustment to achieve the tracking of the weld seam.

The value of laser seam tracking system

Usually, the machine's repetitive positioning accuracy and demonstration reproduction function are already sufficient to meet the requirements of welding.

If you want to know more about robot vision system applications, please visit our website.

One of the main research directions of welding technology in the future is the characteristics of weld tracking technology(2023年05月15日)

Intelligentlaser — 2023-05-11T17:22:17+0900

https://www.intelligent-laser.com/seam-tracking-system-intelligent-solutions/

Weld tracking technology, one of the main research directions for future welding technology

Sensor technology offers many possibilities for welding operations. Some are inexpensive and have limited functionality, while others require significant investment and thoughtful design - its greatest benefit is the cost savings in use. On balance, laser vision seam tracking technology is the best seam tracking solution available.

The robot welding laser seam tracking system, consisting of a laser sensor and a control unit, uses optical propagation and imaging principles to obtain information about the position of each point in the laser scanning area and to complete online real-time inspection of common weld seams through complex programming algorithms. There are corresponding function settings for detection range, detection capability and for common problems in the welding process. The device calculates the deviation between the detected weld seam and the welding gun, outputs the deviation data, and the motion actuator corrects the deviation in real time to precisely guide the welding gun to automatically weld, thus realizing intelligent real-time tracking of the weld seam in the welding process.

Advantages of optical weld seam tracking system welding

1. Ensures safe welding and perfect welds

2. Reduces heat load

3. Increases productivity

4. Enables the welding gun to be in the ideal position

5. Compensates for production, equipment and operating tolerances

6. Reduces programming effort for complex welds

7. Enables consistent and reproducible welds

Visual seam tracking versus arc tracking

With the exception of arc tracking, any weld seam tracking solution for the welding process will add cycle time, but laser seam tracking will add minimal time, typically about a quarter of a second per scan, which is negligible except for position finding applications. Optical seam tracking can reach as fast as 12 meters per minute, so it does not limit the speed of the robot or gantry if high travel speeds are required. Laser seam tracking can also be used for processes other than welding, such as cutting, gluing and grinding.

Laser seam tracking has particular advantages over arc tracking because it does allow the machine to run over the part or offline. Material inconsistencies such as rust, scale, etc. have little to no effect on laser weld tracking because tracking is based entirely on the imaging of the part.

One of the main research directions of future welding technology: weld tracking technology(2023年05月14日)

Intelligentlaser — 2023-05-11T17:21:37+0900

https://www.intelligent-laser.com/seam-tracking-system-intelligent-solutions/

Weld tracking technology, one of the main research directions for future welding technology

Sensor technology offers many possibilities for welding operations. Some are inexpensive and have limited functionality, while others require significant investment and thoughtful design - its greatest benefit is the cost savings in use. Intelligent laser vision seam tracking technology is the best seam tracking solution available.

The laser vision welding seam tracking system, consisting of a laser sensor and a control unit, uses the optical propagation and imaging principle to obtain information about the position of each point in the laser scanning area and to complete the online real-time inspection of common weld seams through complex programming algorithms. There are corresponding function settings for detection range, detection capability and for common problems in the welding process. The device calculates the deviation between the detected weld seam and the welding gun, outputs the deviation data, and the motion actuator corrects the deviation in real time to precisely guide the welding gun to automatically weld, thus realizing intelligent real-time tracking of the weld seam in the welding process.

Advantages of optical seam tracking welding

- Ensures safe welding and perfect welds

- Reduces heat load

- Increases productivity

- Enables ideal torch position

- Compensates for production, equipment and operating tolerances

- Reduces programming effort for complex welds

- Enables consistent and reproducible connections

Visual weld seam tracking vs. arc weld seam tracking

Any robot welding seam tracking solution for the welding process will add cycle time, but laser seam tracking will add the least amount of time, typically about a quarter of a second per scan. Optical seam tracking can reach as fast as 10 meters per minute, so it does not limit the speed of the robot or gantry if high travel speeds are required. Laser seam tracking can also be used for processes other than welding, such as cutting, gluing and grinding.

Principle and Advantages of Laser Vision Seam Tracking System(2023年05月13日)

Intelligentlaser — 2023-05-11T17:20:59+0900

https://www.intelligent-laser.com/

The laser vision system scans the weld seam through laser stripes to obtain the cross-sectional area of the weld seam, the gap of the weld seam, and the height of the left and right edges of the weld seam. It is equipped with an advanced robot interface to transmit data to the robot. The robot can adjust the welding swing, swing frequency, swing left and right dwell time, welding speed, welding current and voltage in real time according to the weld seam section parameters scanned by the laser tracking vision sensor, so as to achieve high-speed, high-quality adaptive welding.

Ⅰ. The principle of robotic seam tracking system

The laser tracking robot adaptive welding system is mainly composed of five parts: robot, operating device, detection head, detection head processor, and computer.

The robot laser seam tracking sensor adopts the principle of laser triangular reflection, that is, the laser beam is amplified to form a laser line, which is projected onto the surface of the measured object. The reflected light is projected onto the imaging matrix through a high-quality optical system. Distance (Z-axis) and positional information along the laser line (X-axis) of the measured surface. By moving the object under test or the probe of the profiler, a set of three-dimensional measurements can be obtained. The obtained information can be used for seam search and positioning, seam tracking, adaptive welding parameter control, seam shape detection, and real-time transmission of information to the manipulator unit to complete various complex welding, avoid welding quality deviation, and realize intelligent welding.

Ⅱ. Advantages of laser seam tracking system

1. Omit a lot of manual teaching operations, making robot welding easier

2. It can realize the identification of various conventional welds

3. Facilitate the expansion of welding automation

How to Realize Seam Tracking and Positioning?(2023年05月12日)

Intelligentlaser — 2023-05-11T17:20:19+0900

https://www.intelligent-laser.com/

Ⅰ. Why does the current welding robot need to install a laser seam tracking system?

1. The actual production status of the user: There are many types of welding products, small batches, and high requirements for welding precision and welding technicians.

2. The cost of workpiece feed improvement is high: update the processing equipment of the original process, design and purchase of high-precision tooling.

3. Welding robots often encounter various technical conditions such as workpiece clamping deviation and sheet metal thermal deformation during the welding production process.

4. Welding robots often need manual repair welding after welding. For small and medium-sized enterprises, it not only increases labor costs, but also increases the repair rate of products.

In order to improve the processing efficiency of the welding robot and reduce the teaching time and difficulty, it is very necessary to match the laser seam tracking system in time.

Ⅱ. How to realize automatic robotic seam tracking and positioning?

Welding Seam Tracking Technology, the Critical Eye-of Industrial Robots(2023年05月11日)

Intelligentlaser — 2023-05-11T17:19:36+0900

https://www.intelligent-laser.com/

Principle of laser welding seam tracking system

Laser vision system, combined with laser and robotic vision technology, can realize the accurate detection of three-dimensional coordinates, and make the robot realize the functions of self-recognition and self-adjustment. It is the core component of robot control. The system is mainly composed of two parts: laser sensor and control host. The laser sensor is responsible for the active acquisition of weld information, and the control host is responsible for the real-time processing of weld information. It guides industrial robots or special welding machines to modify programming paths independently to meet the demand of intelligent production.

The laser seam tracking sensor is mainly composed of CMOS camera, semiconductor laser, laser protection lens, splash guard and air cooling device. The principle of laser triangular reflection is adopted, that is, the laser beam is focused and shaped, and then projected on the surface of the measured object. The diffuse reflection light passes through a high-quality optical system and is imaged on a COMS sensor. After these image information is processed, the working distance, position, shape and other information of the measured object can be generated. By analyzing and processing the detection data, the deviation of the robot programming trajectory can be calculated and corrected. The obtained information can be used for welding seam search and positioning, welding seam tracking, adaptive welding parameter control, and the information can be transmitted to the manipulator unit in real time to complete all kinds of complicated welding, avoid welding quality deviation and realize intelligent welding.

Role of robot laser welding seam tracking system

Manual or semi-automatic welding relies on operator's naked eye observation and manual adjustment to realize the tracking of welding seam.

Value of laser welding seam tracking system

Usually, the repetitive positioning accuracy, teaching and reproduction function of the machine can meet the requirements of welding.