Weld seam tracking and weld seam positioning are two different functions used in welding automation. Weld seam tracking and weld seam positioning are two interdependent technologies that play a very important role in the welding process.
Weld seam positioning, also known as weld seam induction, is the process of detecting the position and direction of the seam on the workpiece before the welding process begins. This is usually achieved by using sensors and software programs to guide the welding gun to the precise position of the seam. The purpose of weld seam positioning is to ensure that welding is accurately applied to the weld seam, which is crucial for ensuring the strength and integrity of the welding. In addition, weld seam positioning helps to reduce defects such as notches, overfilling, and burning through.
There are several methods for locating weld seams, including tactile induction, line induction, and laser induction. Tactile sensing is a method of detecting seams by physically contacting the surface of a workpiece with a wire or nozzle. This method is simple and reliable, but it is slow and has limitations in detecting weld seam gaps. Line sensing is similar to tactile sensing, but it uses a servo motor to quickly move the line up and down as the robot moves along the workpiece. This method can detect butt welds that are difficult to locate using static lines or nozzle contact induction, but requires specific hardware and software. Laser induction is faster than tactile induction and can detect seams with a thickness of 1/16 inch. However, there are limitations in detecting weld gaps, as square butt welds cannot be found.
On the other hand, weld seam tracking is the process of tracking the path of the weld seam during the welding process. This is achieved by using sensors and software programs to guide the welding gun in real-time along the weld seam. The purpose of weld seam tracking is to ensure that welding is accurately applied to the weld seam, even if the position or shape of the seam changes. This is crucial for ensuring welding strength and consistency, even if the workpiece is affected by thermal expansion or other factors that cause deformation.
There are several methods for seam tracking, including arc tracking, laser tracking, and visual tracking. Arc tracking involves measuring arc characteristics during the welding process to determine the difference between the path taught by the robot and the actual weld path. This method is suitable for parts with long or curved welds, which may vary from one component to another. Laser tracking uses laser sensors to follow the weld seam during the welding process, providing real-time feedback to the robot to ensure accurate application of welding to the weld seam. Visual tracking uses a camera to capture weld seam images during the welding process, which are then analyzed by software to guide the robot to move along the weld seam. This method is suitable for components with complex geometric shapes or significantly deformed workpieces.
In summary, weld seam positioning and tracking are important functions in welding automation, but they have different uses and rely on different technologies. Weld seam positioning is used to detect the position and direction of the weld seam before the welding process begins, while weld seam tracking is used to track the path of the weld seam during the welding process. These two functions are crucial for optimizing the efficiency and quality of the welding process, and can help reduce the possibility of defects, improve the strength and integrity of welds.