Principle of the Laser Seam Tracking System
The ATINY laser seam tracking system is an advanced device based on laser vision technology. The system scans the weld seam surface using a laser beam and acquires three-dimensional coordinate information of the weld seam in real-time. The specific principle includes three steps: laser scanning, image processing, and trajectory adjustment:
Laser Scanning: The laser beam is expanded to form a laser line projected onto the weld seam surface. The reflected light is projected onto the imaging matrix through a high-quality optical system, calculating the distance and position information between the sensor and the weld seam surface.
Image Processing: The high-speed image processing unit quickly processes the scanned images, extracting the characteristic information of the weld seam, such as width and position.
Trajectory Adjustment: Based on the extracted weld seam characteristics, the system automatically calculates the optimal welding trajectory and adjusts the motion trajectory of the welding equipment through the control system, ensuring high precision and consistency in the welding process.
Challenges in Reactor Automated Welding
The main challenges faced during reactor welding are as follows:
Complex Structure: Reactors typically have multilayer structures with complex weld seam shapes, and the welding areas are difficult to access. Blind welding by equipment struggles to achieve consistent welding results.
Large Size: Reactors are large in size, making it difficult to observe the weld seam status in real-time during welding. This inability to adjust the welding path in a timely manner leads to welding defects.
Material Characteristics: Reactors often use stainless steel or other high-strength alloy materials, which require high control over welding heat input and weld quality, necessitating precise control of heat deformation and stress concentration during welding.
Low Production Efficiency: Due to the difficulty of reactor welding, traditional automated welding methods are time-consuming, have high labor costs, and result in low production efficiency, making it difficult to meet the demands of modern production.
ATINY's Solution
In response to the challenges of automated reactor welding, ATINY has introduced an automated welding solution based on laser seam tracking systems. This solution combines advanced laser sensing technology, intelligent image processing algorithms, and a precise intelligent control system to effectively solve various challenges faced during reactor welding.
High-Precision Laser Sensor: A high-precision laser sensor is used to capture minute changes in the weld seam in real-time, ensuring the accuracy of the welding path and maintaining stable operation even with complex workpiece shapes.
Real-Time Adjustment Capability: The system has the ability to adjust the welding path in real-time, ensuring consistency and quality in the welding process and reducing welding defects.
High Degree of Automation: It supports fully automated welding, reducing manual intervention, lowering the complexity and error rate of manual operations, and increasing production efficiency.
Strong Compatibility: The system seamlessly integrates with various types of welding robots and equipment, adapting to different production line needs and providing flexible solutions.
Real-Time Monitoring and Feedback: The system can detect abnormalities during the welding process in real-time and display the weld seam status on a screen, allowing operators to make timely adjustments.
Application Case
ATINY's laser seam tracking system has been successfully applied to several automated reactor welding projects in the chemical industry. Below is an actual application case from a chemical enterprise:
The ATINY seam tracking system uses laser sensors to scan and detect the weld seam position in real-time, automatically adjusting the motion trajectory of a Yaskawa welding robot, achieving an efficient and stable welding process. Compared to blind welding based on programmed and taught trajectories, welding quality and production efficiency have significantly improved, while labor costs and human errors have been reduced, enhancing the stability and reliability of the production line.
ATINY's laser seam tracking system, through advanced laser sensing technology and intelligent image processing algorithms, not only solves many challenges in reactor welding but also significantly improves production efficiency and welding quality, bringing greater economic benefits to enterprises. As technology continues to evolve, laser seam tracking systems will play a greater role in more fields, driving continuous advancements in automated welding technology.
