According to industry statistics, when facing curved weld seams and high-speed welding conditions, the leakage rate of ordinary welding sensors is as high as 25%, which seriously restricts the production efficiency and yield rate. The newly developed Laser Weld Tracking Sensor combines four core advantages: micron-level positioning accuracy, excellent response speed, non-contact non-destructive testing and high reliability, which will increase the welding efficiency of a single station by 40% and reduce the defective rate by 60%, and become an "all-in-one" solution to promote the transformation of welding automation. It has become the "all-around" solution to promote the transformation of welding automation.
New Benchmark For Micron-Level Rrecision Welding
The Laser Weld Tracking Sensor revolutionizes welding accuracy with nanoscale positioning and laser measurement technology, and its measurement error is controlled within ±0.01mm, which is 90% more accurate than traditional contact sensors. After actual testing in factories, the pass rate of weld seams has increased from 90% to 98%. Laser Weld Tracking Sensor can accurately track complex curves with a radius of curvature of less than 2µm, which has helped enterprises reduce the scrap rate from 5% to almost zero, and truly realized micron or even nano-scale precision control.
Seconds Scanning Welding Efficiency Jumps
Laser Weld Tracking Sensor is equipped with a high-speed vision scanning system, which utilizes laser light to irradiate the weld surface to form a laser light band, which is received and imaged by a high-definition camera. The scanning frequency is 5 times faster than traditional sensors, and it can capture real-time transient weld changes at the 0.1ms level. Test results show that after adopting Laser Weld Tracking Sensor, the welding cycle of large racks is shortened from 8 hours to 5 hours, and there is no need to stop in the middle of the cycle to calibrate the trajectory.
Exclusive Non-Contact Measurement
Laser Weld Tracking Sensor adopts non-contact measurement technology, completely get rid of the traditional contact probe is easy to wear, easy to welding spatter interference, will not cause damage to the measured object, will not affect the welding process.Laser Weld Tracking Sensor without physical contact with the workpiece can be real-time access to the weld seam 3D data, and can still maintain ± 0.01mm measurement accuracy under high temperature and strong spatter and other harsh conditions, while the average service life of traditional contact sensors in similar environments is only 300 hours, which requires frequent replacement. Under high temperature, strong spatter and other harsh working conditions, it can still maintain ±0.01mm measurement accuracy, while the average service life of traditional contact sensors in similar environments is only 300 hours, requiring frequent replacement.
Highly Reliable & Long-Lasting Operation
The Laser Weld Tracking Sensor is built on an industrial-grade ruggedized architecture for high reliability, withstanding welding spatter, dust, and coolant erosion, with an MTBF of over 50,000 hours and a failure rate of 0.03 failures/kilowatt-hour, a 15x increase in reliability over traditional sensors. Unique adaptive algorithms make it compatible with a variety of materials such as stainless steel, aluminum alloys, as well as highly reflective, dark coating and other complex surfaces, without the need for frequent calibration to maintain ± 0.01mm stable measurement accuracy.
Laser Weld Tracking Sensor successfully transforms the 3D features of the weld seam into structured information, including weld joint coordinates, wrong edges, gaps, etc. through algorithmic processing. This information is transmitted to the robot controller to provide the robot with the trajectory and process parameters required for welding, guiding the robot to weld in real time or correct the workpiece deviation to achieve a perfect welding job. Compared with other solutions, the four core advantages of high accuracy, fast scanning speed, non-contact measurement and high reliability have become the mid-stream pillars of Laser Weld Tracking Sensor in welding automation field.