Principle of the Laser Seam Tracker
The laser seam tracker is an advanced sensing technology that utilizes laser scanning to detect weld seams. By employing precise algorithms and image processing techniques, it captures the three-dimensional information of the seam in real-time. The seam tracker accurately identifies the shape, position, and angle of the weld seam, providing this data to the welding system, which then adjusts the position and angle of the welding head in real-time to achieve high-precision automated welding. The core advantages of this technology are its high resolution and real-time tracking. The non-contact tracking method not only enhances welding accuracy but also avoids defects caused by factors such as workpiece misalignment or thermal deformation.
Challenges in Automated Welding of Wind Turbines
The welding challenges in fan manufacturing mainly include:
Weld Seam Misalignment: Due to inaccuracies in workpiece placement or clamping, weld seams may deviate, making it difficult for automated equipment to maintain seam consistency and welding quality.
High Precision Requirements: Critical components like the fan casing and impeller require extremely high welding precision, with even slight deviations potentially affecting the safe operation of the fan.
Complex Work Environment: Fan manufacturing usually occurs in large-scale factories, where the environment is complex and variable, making it difficult for operators to maintain high efficiency over extended periods.
These challenges make it difficult for traditional automated welding methods to meet the high-precision and high-efficiency demands of modern fan manufacturing.
aTINY's Solution
aTINY's solution for fan welding utilizes the laser seam tracker to achieve real-time detection and tracking of weld seams. The automated control system then adjusts the position and angle of the welding torch to ensure high precision and quality throughout the welding process.
High-Precision Seam Tracking: Through laser scanning and intelligent algorithms, the seam tracker can precisely locate weld seams and adjust the welding path in real-time to ensure high precision. Even in complex weld seams of large fan components, the tracker efficiently provides stable and accurate welding guidance.
Strong Adaptability: aTINY's solution is compatible with various complex weld seam shapes and materials, meeting the welding needs of different fan models and specifications.
Seamless Integration: The aTINY laser seam tracker also supports collaboration with various brands of robots, specialized machinery, and other welding equipment and control systems.
Anti-Interference Technology: aTINY sensors incorporate unique anti-interference technology, effectively resisting interference from smoke, spatter, and other factors, ensuring welding accuracy and stability.
Case Study
In a practical application at a tunnel fan manufacturing company, the aTINY laser seam tracker, in collaboration with specialized machinery, provided real-time tracking of weld seam positions and shapes. The sensor guided the welding equipment to follow the predetermined path for precise welding, significantly improving welding accuracy and efficiency, and delivering substantial economic benefits to the company.
Additionally, the aTINY seam tracking system has been successfully applied in other fields, such as pressure vessel welding, box welding, and automated welding of spiral pipes, demonstrating its broad applicability and strong technical capabilities.
Conclusion
By leveraging its advanced laser seam tracking technology and integrating with various welding equipment, aTINY has successfully addressed many welding challenges in fan manufacturing. In the future, as technology continues to advance, laser seam tracking will play a crucial role in driving the intelligent transformation of China's manufacturing industry. aTINY remains committed to technological innovation and product development, offering customers superior and efficient automated welding solutions.
