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2D/3D profile sensor for weld seam inspection

Weld Seam Inspection
With 2D/3D Profile Sensors

Du­ring wel­ding, the type of ma­te­rial, the wel­ding tech­ni­que used and the am­bient con­di­tions de­ter­mi­ne the re­sult. It is the­re­fo­re im­por­tant to check the wel­ded joint af­ter­wards. For this pur­po­se, wel­ding sys­tems are equip­ped with the in­no­va­ti­ve weCat3D 2D/3D pro­fi­le sen­sors for weld seam ins­pec­tion.

Outs­tan­ding Per­for­man­ce and Ef­fi­ciency: The weCat3D Se­ries for Wel­ding Sys­tems

After the wel­ding pro­cess has been com­ple­ted, the re­sult must be chec­ked. Irre­gu­la­ri­ties such as mis­sing, dou­ble, un­du­la­ted or other faulty welds are re­liably de­tec­ted by 2D/3D pro­fi­le sen­sors and out­put via the de­fi­ned in­ter­fa­ce. A com­mon au­to­ma­tic test method is vi­sual ins­pec­tion. The use of a pro­fi­le sen­sor of­fers de­ci­si­ve ad­van­ta­ges in this pro­ce­du­re: the time re­qui­red for chec­king and analy­zing the wel­ding seams is re­du­ced without com­pro­mi­sing on the qua­lity of the ins­pec­tion.
  • Pre­ci­se chec­king along the wel­ding seam
  • Ex­ce­llent pro­fi­le qua­lity – even on re­flec­ti­ve sur­fa­ces
  • Com­pact hou­sing (IP67)
  • Easy sen­sor in­te­gra­tion thanks to exis­ting SDKs and the stan­dard Ether­net TCP/IP in­ter­fa­ce
  • High pro­fi­le den­sity for the sma­llest error de­tec­tion with Z re­so­lu­tion from 2 μm 
  • Ma­te­rial and color in­de­pen­dent 
  • High mea­su­re­ment fre­quency



How the Weld Seam Ins­pec­tion Works

Animated analysis of the weld
Du­ring the vi­sual weld seam ins­pec­tion, the pro­fi­le sen­sor is gui­ded along the real wel­ding seam. The sen­sor is po­si­tio­ned so that the pro­fi­le line ge­ne­ra­ted is per­pen­di­cu­lar to the wel­ding seam. The joi­ning of the in­di­vi­dual pro­fi­les in the ap­pli­ca­tion soft­wa­re crea­tes a 3D image, which is exa­mi­ned by the soft­wa­re for irre­gu­la­ri­ties – ta­king into ac­count a set to­le­ran­ce. If de­via­tions are found du­ring the sub­se­quent eva­lua­tion, a co­rres­pon­ding sig­nal is out­put by the soft­wa­re.

Ver­sa­ti­le for Wel­ding Pro­ces­ses

Automated industrial welding
With the fo­llo­wing types of wel­ding, for exam­ple:
 
  • MIG – Metal Inert Gas
    Metal wel­ding with inert, i.e. inac­ti­ve gases
     
  • MAG – Metal Ac­ti­ve Gas
    Metal wel­ding with ac­ti­ve gases
     
  • ​​​​​​WIG – Wol­fram Inert Gas
    Metal wel­ding with a non-​melting pure or alloy tungs­ten elec­tro­de
    ​​​​​​​
  • Laser wel­ding (EN ISO 4063: Pro­cess 52)
    Laser wel­ding per­mits high wel­ding speeds with highly pre­ci­se re­sults 

Irre­gu­la­ri­ties After Applying the Wel­ding Seam

No seam

Welding seam: No seam

Hole

Welding seam: Hole

Mis­sing edge for­ma­tion

Welding seam: Missing edge formation

Pore

Welding seam: Pore

Pro­tru­sion

Welding seam: Protrusion

Cur­va­tu­re

Welding seam: Curvature

Seam angle

Welding seam: Seam angle

Seam angle

Welding seam: Seam angle

Wel­ding seam po­si­tion

Welding seam: Welding seam position

Root sag

Welding seam: Root sag

Clea­ran­ce

Welding seam: Clearance

Root con­ca­vity

Welding seam: Root concavity

A-​dimension

Welding seam: A-dimension

A-​dimension cam­ber

Welding seam: A-dimension camber

Dip­ping

Welding seam: Dipping

Ar­ching

Welding seam: Arching

Seam burr

Welding seam: Seam burr

Edge height

Welding seam: Edge height

实例和合作

wen­glor 创新传感器用于不同行业,其多功能性得到了证明。与机器人单元和集成商的软件结合使用,可以保证所要的焊接结果,例如最大程度降低后续成本,提高产品可靠性。因此广泛用于诸多行业:
 
  • 汽车行业
  • 轨道交通行业
  • 航空业
  • 重型机械制造
  • 特种机械制造
  • 钢铁行业

在与我们客户合作时,了解 2D/3D 轮廓传感器的多功能性:

El paso ló­gi­co

Nues­tro socio EHR, me­dian­te su soft­wa­re TIVIS®, nos pro­por­cio­na una he­rra­mien­ta con la que se pue­den eva­luar los cor­do­nes de sol­da­du­ra re­gis­tra­das por el sen­sor de per­fi­les 2D/3D weCat3D con res­pec­to a di­fe­ren­tes pa­rá­me­tros: De este modo, es po­si­ble de­tec­tar de forma fia­ble, por ejem­plo, la lon­gi­tud, la an­chu­ra, el án­gu­lo, las grie­tas, los bor­des o el tipo de cur­va­tu­ra de los cor­do­nes de sol­da­du­ra ha­bi­tua­les.

weCat3D

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