Robot Welding Laser Seam Tracking

Robot Welding laser seam tracking

Laser seam tracking is an "online" process where a sensor system actively guides the robot during the welding operation . Here is how it works:

Laser Triangulation: A laser diode projects a laser line onto the workpiece in front of the welding torch. A camera (or optical sensor) in the sensor head captures the reflected light. By analyzing the deformation of this laser line, the system generates a 3D profile of the weld seam .

Real-Time Correction: The sensor continuously sends this profile data to the robot's controller. Specialized software (e.g., wenglor's uniVision "Profile Weld Seam Tracking" module) processes this data in real-time to identify the seam's exact position and geometry . The robot then dynamically adjusts the torch path to perfectly follow the joint, compensating for part misplacement, thermal distortion, or manufacturing tolerances .

🔧 System Construction

 

Sensor Head: A rugged, compact unit that houses the laser projector and the camera. It is designed to withstand the harsh environment of a welding cell, including spatter, heat, and electromagnetic interference.

Controller Unit: A powerful processor that acts as the system's brain. It analyzes the images from the sensor, calculates the seam position and geometry, and sends correction signals to the robot controller.

Interface Cables: Robust cables for power, data communication between the sensor and controller, and integration with the robot control system.

Mounting Bracket: A precision bracket to securely attach the sensor head to the welding torch on the QJAR robot, ensuring a fixed and known positional relationship between the torch and the sensor.

Software: User-friendly software for calibrating the system, teaching seam types, and setting parameters.

⚙️Operating Principle

Laser Seam Tracking, also known as Joint Tracking, operates on the principle of laser triangulation.

Laser Projection: A semiconductor laser diode projects a laser line or a series of points onto the workpiece surface, just ahead of the welding torch.

Image Capture: A high-resolution camera, housed in the same sensor head, captures the reflection of this laser line as it falls on the seam.

3D Profile Creation: The sensor's controller processes the captured image. Since the laser line will deform at the joint (e.g., a groove, lap, or fillet), the system can generate a precise 3D profile of the seam geometry.

Real-Time Adjustment: This profile data is continuously fed to the robot controller (e.g., QJAR controller). The controller then makes real-time adjustments to the robot's path, torch position, and can even adapt welding parameters (like voltage or wire feed speed) to compensate for seam misalignment, part variation, or thermal distortion

This "Online" method of tracking during the welding process is highly productive, as it requires only a single "search and weld" cycle and effectively compensates for heat-induced distortion

1.Robotic Manipulator (6-Axis Articulated Robot)

The main technical parameter of the robot:

1. Effective radius and load of robot: 1700mm

2. Robot repeat positioning accuracy: ± 0.05mm

3. Payload: 12kg

Robot Mass: 240KG

4. Power supply: three-phase five wire AC380 (± 10%) V, frequency: 50HZ

5. Main power protection level: IP56/IP67

6. Main processing parts: parts welding processing (depending on customer product shape and process requirements)

Laser seam tracking is invaluable in industries where precision and adaptability are required.

Construction Industry Applications:

Structural Steel Fabrication: Used for welding beams, columns, and trusses for buildings and bridges. The system compensates for the thermal distortion that occurs in long weld seams, ensuring structural integrity.

Pipe Welding: Ideal for circumferential welds on large-diameter pipes used in pipelines. It ensures leak-proof joints even if pipe alignment isn't perfect .

Heavy Equipment Manufacturing: For fabricating frames and structural components for construction machinery, where high-strength welds are critical

Factory & General Manufacturing Applications:

Automotive & Aerospace: These sectors benefit from the high precision for complex welds on chassis, frames, and critical components like exhaust systems or turbine blades .

High-Mix, Low-Volume Production: Perfect for job shops or factories that frequently switch between different products. The system minimizes reprogramming time and allows for quick adaptation to new weld seams .

Welding of Variable or Imperfect Parts: Compensates for inconsistencies from upstream processes like casting or pressing, reducing the need for expensive, perfect jigs and fixtures

Six axis robot system: QJR12-1700

☑️ The QJR12-1700 robot is a highly efficient robot specifically designed for the field of welding. It has six axis and is driven by AC servo, shortening the welding cycle time with the fastest action speed. The robot cable is embedded inside the robotic arm and base, saving space and achieving high-density configuration, easily avoiding interference between fixtures and workpieces. The arm moves freely, stably, and has high precision in repeated positioning, making it easy to coordinate with welding power sources, welding heads, wire feeding mechanisms, and displacement machines. The QJR12-1700 robot has a movement radius of 1550mm, a maximum load capacity of 12kg, and a repeated positioning accuracy of ± 0.05mm. It adopts a hollow wrist structure, which can effectively ensure high-quality welding processes.

Wuhan HJZ Laser Technology Co.,Ltd

The company covers an area of over 2000 square meters and has a single garden style factory building with a 5-star decoration standard. The team size is 50 people, and the company is in a leading position in the competition in similar products industry.

Professional team

We have over 20 R&D patent certificates and honors such as CE, SGS, and National High tech Enterprise.We have professional technical talents who have served the laser industry for 15 years and can customize the laser equipment you want

7x24 hours delivery

Our team can provide a 7x24 hour online service team, achieving a group of customers.exporting to over 100 countries and regions, and winning the trust and good reputation from the customers

5000

Floor space(㎡)

5

Production lines

9

R&D engineers

 

 

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