Seam Tracking
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Seam Tracking University of Twente D reb b el Institu te
The Netherlands
laser beam plasma weld
meltpool
keyhole base material
Poor laserweld due to misalignment of the laser beam.
In laser welding a high energy laser beam is scanned along the seam between two metal parts and in this way creating a melt pool at their interface. After irradiation, the melt pool resolidifies, joining the two plates together. High-speed laser welding requires accurate positioning of the laser beam relative to the seam to be welded (typically better than 50um). For this purpose a seam tracking system is required.
A seam tracking system measures the seam to be welded and guides the laser beam, which is manipulated by a robot, over the seam. Such a system consists of: A seam sensor to measure seam coordinates, A data processing unit, which may take measured signals from the weld process itself, A path generation unit.
Seam coordinates Data processing
Process signals
Seam location Path generation
Seam sensor Laser beam
Robot position
Seam
Robot controller Robot
Functional layout of robot-assisted laser welding with seam tracking.
There are 2 approaches: First-teach-then-weld: the seam is first measured. Next the seam is welded blind, Track-and-weld: simultaneous measuring and welding.
Seam
Low power laser diode (1) Low power laser diode (2)
left plate Steel (1mm) right plate Steel (1mm)
High power laser beam (Nd:YAG)
Camera
Welded seam
left plate Steel (1mm) right plate Steel (2mm)
left plate Steel (1mm) tilted right plate Steel (1mm) Seam Plates to be welded
Configuration of optical sensor based on structured lighting and triangulation. The 2 laser diodes project a line on the work piece, which is monitored by the CCD camera.
Tailored blank: left plate Al (2mm) right plate Cu (0.2mm)
Seam Field of view of sensor
Seam
Field of view of sensor
Laser spot
Laser spot
To ensure that the seam remains in the Field of View (FoV) of the camera, in the case of strongly curved seams, the sensor is “rotated in the direction of the seam”. This requires an additional axis on the robot.
prof. dr. ir. J.B. Jonker prof. dr. ir. J. Meijer dr. ir. G.R.B.E. Römer
First results of laser welding with seam tracking. Material: Steel E340 (thickness 1mm), power Nd:YAG laser 1.6kW, welding speed 75 mm/s.
Drebbel Institute, WB-WA University of Twente P.O. Box 217, 7500 AE Enschede The Netherlands [email protected] http://www.rt.el.utwente.nl/drebbel/
The Netherlands
laser beam plasma weld
meltpool
keyhole base material
Poor laserweld due to misalignment of the laser beam.
In laser welding a high energy laser beam is scanned along the seam between two metal parts and in this way creating a melt pool at their interface. After irradiation, the melt pool resolidifies, joining the two plates together. High-speed laser welding requires accurate positioning of the laser beam relative to the seam to be welded (typically better than 50um). For this purpose a seam tracking system is required.
A seam tracking system measures the seam to be welded and guides the laser beam, which is manipulated by a robot, over the seam. Such a system consists of: A seam sensor to measure seam coordinates, A data processing unit, which may take measured signals from the weld process itself, A path generation unit.
Seam coordinates Data processing
Process signals
Seam location Path generation
Seam sensor Laser beam
Robot position
Seam
Robot controller Robot
Functional layout of robot-assisted laser welding with seam tracking.
There are 2 approaches: First-teach-then-weld: the seam is first measured. Next the seam is welded blind, Track-and-weld: simultaneous measuring and welding.
Seam
Low power laser diode (1) Low power laser diode (2)
left plate Steel (1mm) right plate Steel (1mm)
High power laser beam (Nd:YAG)
Camera
Welded seam
left plate Steel (1mm) right plate Steel (2mm)
left plate Steel (1mm) tilted right plate Steel (1mm) Seam Plates to be welded
Configuration of optical sensor based on structured lighting and triangulation. The 2 laser diodes project a line on the work piece, which is monitored by the CCD camera.
Tailored blank: left plate Al (2mm) right plate Cu (0.2mm)
Seam Field of view of sensor
Seam
Field of view of sensor
Laser spot
Laser spot
To ensure that the seam remains in the Field of View (FoV) of the camera, in the case of strongly curved seams, the sensor is “rotated in the direction of the seam”. This requires an additional axis on the robot.
prof. dr. ir. J.B. Jonker prof. dr. ir. J. Meijer dr. ir. G.R.B.E. Römer
First results of laser welding with seam tracking. Material: Steel E340 (thickness 1mm), power Nd:YAG laser 1.6kW, welding speed 75 mm/s.
Drebbel Institute, WB-WA University of Twente P.O. Box 217, 7500 AE Enschede The Netherlands [email protected] http://www.rt.el.utwente.nl/drebbel/
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