Laser Weld Tracking Sensor
The automatic weld 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.
Advantages of Laser Weld Tracking Sensor
High Precision
Laser weld tracking sensors possess high-precision measurement capabilities,achieving micrometer or even nanometer-level measurement accuracy,suitable for measuring weld seams of various complex shapes.
Fast Scanning
Laser beam scanning is rapid,enabling quick scanning and measurement,thereby improving work efficiency.
Non-contact Measurement
Laser weld seam tracking sensors employ non-contact measurement methods,causing no damage to the tested object and having no impact on the welding process.
High Reliability
Laser weld tracking sensors exhibit high reliability and stability,allowing for continuous operation over extended periods with low maintenance costs. These sensors can adapt to various materials and colors of the tested objects,demonstrating strong adaptability.
Why Choose Us
Profession team
We specialize in the application of 3D laser weld tracking sensors as the core, the company provides customers with 3D sensors, automatic systems exempt from programming, welding robots and completed solutions for welding specialized machine systems. Focusing on improving our own R&D and innovation capabilities, owning unique and innovative ideas in the fields of optics, electronic hardware and algorithms, and aspires to design optimal solutions for complex welding operations.
Advanced equipment
Our company has introduced advanced production equipment both domestically and internationally, including Debugging machine machines, Production machine tools, etc., which can complete the entire production process from raw material processing to product assembly.
Our certificate
Complete quality control system has been established with the ISO9001 Certification,CE Certification.
Production market
Our products support global shipping and the logistics system is complete, so our customers are all over the world. The products are not only domestically and internationally, but also exported to multiple regions such as Europe, America, Africa, and South America, earning unanimous recognition from domestic and foreign users.
Working Principles of Laser Weld Tracking Sensors
Laser Emission
The sensor emits a laser beam directed onto the workpiece surface.
01
Surface Scanning
The sensor may use the laser beam to scan the workpiece surface,acquiring topological information to understand the position and shape of the weld seam.
02
Reflection Detection
The sensor receives signals reflected back by the laser beam.By analyzing the characteristics of the reflected signal,the sensor can determine the position and shape of the weld seam.
03
Real-time Feedback
The sensor may provide real-time feedback,enabling the control system to make adjustments to welding robots or automated welding equipment based on calculated weld seam position and shape information,facilitating automatic seam tracking and welding.
04
Applications of Laser Weld Tracking Sensors
Steel structure welding
In steel structure welding processes,manual welding is challenging and inefficient due to the large size and complex shape of the workpieces.Weld seam tracking technology can automatically identify and track weld seams,improving welding quality and efficiency.
Shipbuilding
Shipbuilding involves a large amount of welding work.Weld seam tracking technology can achieve precise tracking of ship weld seams,improving welding quality and efficiency while reducing labor intensity.
Automobile manufacturin
Weld seam quality and accuracy are crucial for the safety and comfort of automobiles.Weld seam tracking technology can achieve precise tracking of automobile weld seams,improving welding quality and efficiency while reducing manufacturing costs.
Aerospace
The aerospace industry demands extremely high welding quality.Weld seam tracking technology can achieve precise tracking of aerospace weld seams,ensuring welding quality meets high standards.Weld seam tracking technology is an important means of achieving efficient and precise welding automation.With the continuous development and application of this technology,it will bring more opportunities and challenges to the welding industry,driving welding technology towards greater intelligence and automation,and making greater contributions to the development of the manufacturing industry.
Structure of Laser Weld Tracking Sensor
Laser vision sensor
Compact laser vision sensors are typically installed on the welding torch. A laser diode inside the sensor emits a visible laser beam, which, after passing through an aperture, becomes a fan-shaped light band projected onto the workpiece. The sensor contains a CCD camera set at an angle relative to the laser diode, capturing the reflected light from the workpiece surface to image the geometric contour of the joint onto the CCD. Utilizing optical triangulation, horizontal features can be detected, and the height between the sensor and the workpiece can also be determined. The role of the sensor is to convert the measured physical quantity into a useful electrical signal corresponding to it, to meet the requirements of information processing and control. The control system analyzes and processes the signals from the sensor to obtain control signals. The actuator typically consists of motors and cross sliders, with the servo motor controlled by the control signal.
Image preprocessing
Image processing in welding robot vision systems can generally be divided into two aspects: first, enhancing, filtering, and binarizing the acquired raw images to remove noise and make the original image clearer with more pronounced edge features, i.e., preprocessing; second, performing edge detection, feature extraction, etc., on the preprocessed images to accurately obtain the center information of the weld seam, facilitating coordinate adjustments by the robot to meet welding quality requirements. A study on real-time image processing methods for visual weld seam tracking has been conducted, initially employing image enhancement to increase image contrast, using median filtering to remove image noise, and extracting the target image from the background image using binarization. In the post-processing phase, key technologies for image processing in laser vision weld seam tracking systems, such as extracting the centerline of micro-light bands and detecting feature points, have been proposed. The centerline extracted using the axial transformation method is single and continuous, and feature points are detected conveniently and reliably using the slope analysis method. This processing method can accurately detect weld seam feature points, with fast processing speed, meeting the real-time requirements of the tracking system.
Adjusts the position
The above content is an analysis of the structure of the laser vision weld seam tracking system. Before the welding operation begins, the laser vision weld seam tracking system adjusts the position of the welding torch to align it with the center of the weld seam. Then, the power is turned on, the system starts working, and the program begins to run. The CCD in the sensor continuously monitors the image in real-time. A timer is started by the software, adjusting the time interval of the timer according to the welding speed requirements, capturing a frame of images at regular intervals. Through the program, real-time processing of the images is conducted to obtain the center of the weld seam. The deviation of the current weld seam center from the initial weld seam center is used as the detection quantity, and the adjustment amount is output to the robot controller to control the robotic arm to guide the welding torch for automatic tracking.
The Laser Weld Tracking Sensor Has a Rigorous Structural Design
The laser, serving as a structured light source, projects laser stripes onto the working surface below the sensor at a predetermined angle. The CCD directly observes the stripes beneath the sensor. The sensor is installed at a predetermined distance in front of the welding torch, allowing it to observe the weld seam. During tracking, welding speed and forward distance are used to calculate the delay time, ensuring that the welding torch progresses along the weld seam.
It relates to the technical field of laser weld tracking sensor and discloses a laser weld seam tracking sensor based on dual-camera image overlaying. The sensor comprises a casing with an opening downwards, a main view camera, an auxiliary camera, a laser driver and a laser. The laser driver is fixed on the upper portion on the inner side of the casing, a main view camera support is fixed in the middle on the inner side of the casing, the main view camera is fixed on the main view camera support, and a narrow band filter with the same wave length with the laser is fixed on the front side of a lens of the main view camera; the laser support is fixed on the lower portion on the inner side of the casing, and the laser is fixed on the laser support.
According to the laser weld tracking sensor, the structure is reasonable and compact, the usage is convenient, and automatic tracking of V-shaped weld seams and butt-joint gapless weld seams is achieved through matched usage of the laser driver, the main view camera, the laser and the auxiliary camera. The sensor has the advantage of being good in tracking efficiency, and the weld efficiency and the weld quality are improved.
How To Choose The Right Laser Weld Tracking Sensor
Technical level
Automated welding uses sensing and measurement technology to detect the position deviation of the welding gun from the center of the laser weld tracking sensor. This deviation is then calculated by a computer and adjusted in real-time by a welding robot, ensuring the welding gun is always aligned with the laser weld tracking sensor, thereby achieving automated welding. Attention should be paid to the production technology when choosing a laser weld tracking sensor manufacturer. The weld seam tracking technology depends on the manufacturer's technological and production level. Therefore, it's important to choose a manufacturer with mature production technology.
Company qualifications
When choosing a laser weld tracking sensor manufacturer, it is important to consider the company's qualifications. It is advisable to select manufacturers with comprehensive qualifications and their own patented technology.
Service level
The service level of the laser weld tracking sensor manufacturer should also be considered. It is important to pay attention to the technical level of the manufacturer's service personnel and their response speed. Moreover, to provide timely, professional, and localized technical and after-sales services, quickly respond to customer needs and provide efficient and professional technical and after-sales services.
Laser Weld Tracking Sensor System Adapted to New Song Robotics in Steel Structure Welding
In laser tracking, a laser weld tracking sensor is mounted on the robot arm and is aimed at the workpiece. The laser sensor continuously measures the distance between the sensor and the workpiece, and feeds this information back to the robot controller. The robot controller uses this information to make adjustments to the robot arm’s position and movement, ensuring that the welding tip remains precisely aligned with the workpiece.
The use of laser tracking in robotic welding provides several benefits. By ensuring precise and accurate welding, laser tracking helps to reduce the risk of defects and improve the quality of the welds. It also helps to reduce the amount of setup time required for a welding job, as the robot can quickly and accurately adjust its position without the need for manual intervention. Additionally, laser tracking can help to increase the speed and efficiency of robotic welding, as the robot can move more quickly and smoothly along the welding path.
Non-contact laser vision system enables high-speed, high-precision localization and real-time tracking of weld seams, greatly simplifying robot applications. Possesses the capability to resist arc light, smoke, spatter, spot welding, and electromagnetic interference, adapting to various complex welding environments. Applicable to all welding processes, with high precision, fast processing speed, and strong anti-interference ability. Enables control of the welding torch, significantly reducing the labor intensity of welders and the influence of human factors, ensuring weld quality and improving welding efficiency.
In practical applications, the laser weld tracking sensor system dynamically locates and scans the starting and ending points, providing precise, real-time weld seam positioning and tracking information to the robot, enabling efficient and stable welding on steel structural components. This not only significantly improves welding efficiency but also notably enhances weld seam quality, bringing significant economic benefits and market competitiveness to the enterprise.
The integration of creative laser weld tracking sensor with new song robotics not only achieves high-precision and high-efficiency welding processes but also reduces labor costs and improves production safety, bringing tangible economic benefits to the enterprise. With the continuous advancement of technology and the deepening development of the market, seam tracking systems will continue to create more value in the field of automated welding of steel structures.
Our Factory
Suzhou Full-v was founded in 2019 and has served thousands of users both domestically and internationally, gaining unanimous recognition from users. The Full-v 3D laser intelligent weld seam tracking system has achieved full coverage matching among mainstream robot manufacturers both domestically and internationally, and has the characteristics of simplicity, reliability, and widespread use. The company is committed to providing open and customized optoelectronic sensor equipment and technical services, always prioritizing product quality and user experience. With a spirit of continuous improvement as a craftsman, we provide customers with reliable and stable products.
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FAQ
Q: What is a laser weld tracking sensor?
Q: What role do laser weld tracking sensors play in ensuring weld consistency?
Q: How do laser weld tracking sensors support complex welding geometries?
Q: Are laser weld tracking sensors suitable for high-speed welding applications?
Q: What are the safety considerations when using laser weld tracking sensors?
Q: How can laser weld tracking sensors help in reducing material waste?
Q: Can laser weld tracking sensors be used for monitoring weld penetration depth?
Q: What are the data analysis capabilities of laser weld tracking sensors?
Q: How do laser weld tracking sensors contribute to quality assurance in welding?
Q: How can laser weld tracking sensors support additive manufacturing processes?
Q: How does a laser weld tracking sensor work?
Q: What are the key advantages of using a laser weld tracking sensor?
Q: What types of welding applications can benefit from laser weld tracking sensors?
Q: What are the main components of a laser weld tracking sensor system?
Q: How can laser weld tracking sensors improve weld quality?
Q: Can laser weld tracking sensors be integrated with robotic welding systems?
Q: How do laser weld tracking sensors contribute to process optimization?
Q: Are there different types of laser weld tracking sensors available?
Q: What are the considerations for selecting a laser weld tracking sensor?
Q: How can laser weld tracking sensors enhance productivity in manufacturing?
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