How to Choose Laser Vision Seam Tracking System? - Blog4evers

Laser seam tracking is typically integrated into production lines and manufacturing processes that rely on automated welding, which is mostly done by welding robots. This includes the automotive and aerospace industries, as well as the manufacturing of construction equipment and heavy machinery, the shipbuilding industry, and metal fabrication.

A laser seam tracking sensor is used to significantly enhance the precision process by following the weld seam and guiding the automated welder. This has a positive effect on productivity, as it allows for a faster production project.

Namely, by accurately tracking the weld seam, the laser tracker reduces the need for manual adjustments, which leads to better positioning, faster welding, and, subsequently, a significantly increased throughput. At the same time, the likelihood of defects such as missed seams or inconsistent weld penetration is greatly reduced.

Furthermore, more advanced laser seam tracking systems are quite adaptable to variations in the weld seam and can accommodate any changes in alignment or seam geometry in real time. These factors contribute to a significant reduction in costs that are otherwise associated with re-work.

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Since welding technologies and welding techniques differ across different materials and applications, it’s only reasonable to conclude that laser seam tracking sensors differ as well.

Not all laser seam tracking systems are the same. Some rely on laser displacement sensors to perform 1D measurements, while others rely on laser profilers to perform 2D scans. In either case, both systems measure the distance between the sensor and the target surface, with the aim of identifying and tracking weld seams. In most cases, they do this by measuring height, where they either take a series of 1D measurements or 2D scans that detect height variations.

Selecting the right laser weld seam tracking solution involves considering the specific requirements of your welding process, its environmental conditions, the materials and types of workpieces the process revolves around, and the level of accuracy and precision required by your application.

KEYENCE offers a comprehensive range of 2D/3D Laser Profilers that are great for all sorts of welding applications. So, if you’re interested in upgrading your current welding process by integrating laser seam tracking, don’t hesitate to contact KEYENCE and inquire about integration options with your current welding setup.

In today’s highly competitive market, manufacturers must stay both lean and efficient. Taking advantage of the different seam tracking options available for your welding projects is one way to gain an edge.

Here at Bancroft Engineering, we understand the importance of optimizing your welding process.

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Tactile Seam Tracking

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Tactile seam tracking systems track the seam using a sensor with a tip that physically touches along the length of the seam about 2-3” in front of the arc. When a change in location or alignment is detected, the system responds and adjusts to the correct position. It can be used in almost any welding process.  Tactile seam tracking is very versatile and works well on any material type. This option offers a great balance between cost and flexibility.

One disadvantage to tactile seam tracking is that the torch is adjusting in real time according to where the probe is touching not where the torch is welding.  If the probe is 3” in front of the arc and a quick drastic change to the seam is detected the arc may actually move outside of the seam. To solve this problem the tracker can be paired with another type of control system to delay the correction in relation to the travel speed of the weld head or part.

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Through Arc Seam Tracking

 Through arc seam tracking is a type of 2-axis real-time tracking.  The tracking occurs as the weld is being deposited and adjusts by monitoring the voltage across the arc.  In order to shift along 2 axes’ with through arc tracking weaving is required.  As the tip to work distance changes so does the voltage across the arc.  This change in voltage is monitored and used to adjust the path of the torch, maintaining proper weld position in the joint.

Laser Vision Seam Tracking

Laser based vision tracking, also referred to as optical tracking, involves a laser beam device which hits the welding surface, reflects off and bounces back to the sensor. With this technology, the sensor then recognizes exactly where the seam is located. Laser vision seam tracking is highly reliable and great for high speed welding applications for both small and large parts.

Touch Sensing

Touch sensing, or wire touch sensing, is the physical touching of the weld wire to the welding surface to detect the joint. Most commonly used in robotic welding applications, this type of seam tracking uses low voltage through the welding wire or torch tip to search and detect the welding surface and seam.  The seam needs to be detected prior to welding so the cycle time can be double or more compared to that of other methods.

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The bottom line for companies manufacturing welded products is to achieve the highest quality at the lowest cost. The best measure of how well this is being achieved is the metric called Overall Equipment Effectiveness (OEE). SERVO-ROBOT has just released their newest AUTO-TRAC/PWP laser vision seam tracking system that dramatically improves weld productivity, quality and up-time which are the three factors influencing the OEE metric.

AUTO-TRAC/PWP shown in the Figure has achieved new levels of welding performance while being the simplest laser vision seam tracker ever to use. If you can operate an iPad® you can run the AUTO-TRAC/PWP. One can install this system on your new equipment or it is setup to easily retrofit to existing welders which are manually operated or utilize mechanical probe for guidance. The heart of the system is the digital high speed laser camera head which is the most powerful for its size on the market today. It has a large field of view combined with high resolution that allows this system to handle products ranging from thin sheet metal to 50mm thick steel. In the past, either a camera had to be optimized for small or large weld joints but could not do both. This is no longer a limitation.

As great as the hardware performs, the intuitive software and friendly user interface are really what sets the SERVO-ROBOT AUTO-TRAC/PWP system apart from anything else on the market. While one can get caught up with numbers like the system’s camera speed in thousands of profiles/second or the resolution in microns, what are really important is what one can do with all this power and how easy the system is to use. Features from SERVO-ROBOT’s AUTO-TRAC/PWP that have not previously been available from anyone include those shown in Table below. These features directly improve performance when welding products ranging from storage tanks to ships to bridges.

What is the feature How this benefit improves productivity and quality Weld joint validation Validates that the joint fit-up meets the weld procedure requirement before welding is allowed to start, thus greatly reducing rework and scrap Real time adaptation to part Compensates within process capability for joint variability, including excessive gap , to make an acceptable weld Real time weld inspection Can inspect in real time with a camera located behind the welding torch or by using a second pass scan Automatic joint location If the joint is outside of the camera FOV, the system automatically searches till the weld joint is found Controller can run 2 cameras One can simultaneously track the joint and inspect the weld to insure optimized welding takes place

Besides doing its main task of seam tracking, the ability to monitor the overall welding process provides useful data to facilitate Six Sigma continuous improvement efforts. Useful information includes part fit-up variability, system up-time and productivity metrics.