Principle of Laser Seam Tracking
The laser seam tracking system uses laser sensors to monitor the position and shape of the weld seam in real time and adjusts the welding path through intelligent algorithms. The main steps of its working principle are:
Laser Scanning: The laser sensor scans the welding area to obtain three-dimensional shape data of the weld seam.
Data Processing: The collected seam shape data is transmitted to the control system, where specific algorithms process and analyze the data to determine the actual position and shape of the weld seam.
Path Adjustment: Based on the analysis results, the control system adjusts the position and movement trajectory of the welding head in real time, ensuring the welding torch always follows the center of the seam.
Feedback Control: During the welding process, the laser sensor continuously monitors the seam position and welding quality, providing feedback to the control system for dynamic adjustments to ensure welding quality stability.
Challenges in Automated Welding of Water Heater Inner Tanks
Welding water heater inner tanks poses several challenges:
Complex Seam Shapes: Inner tanks usually have a cylindrical design with curved seams, making it difficult for traditional welding methods to ensure uniformity and consistency.
High Temperature and Pressure Environment: Water heaters need to withstand high temperatures and pressures, requiring weld seams to have excellent strength and sealing. Any slight mistake can result in weld leakage or cracks.
Material Characteristics: Inner tanks are mostly made of stainless steel, which is corrosion-resistant and strong but prone to deformation and welding defects during welding, demanding high welding process standards.
Production Efficiency: Increasing market demand makes production efficiency a crucial factor. Manual or semi-automatic welding methods cannot meet the requirements for efficient production.
ATINY’s Laser Seam Tracking Solution
In response to these welding challenges, ATINY has introduced a laser seam tracking system, providing a comprehensive automated welding solution.
System Components
ATINY's laser seam tracking system consists of laser sensors, a control system, welding equipment, and software. The laser sensor monitors the seam position in real time, the control system handles data processing and path adjustment, the welding robot performs the welding operations, and the software system offers a human-machine interface and data management functions.
Functional Features
High-Precision Seam Tracking: Through laser scanning and data processing technology, the system can achieve high-precision seam tracking, ensuring the welding torch always follows the seam center.
Real-Time Dynamic Adjustment: During welding, the system can monitor the seam position and welding quality in real time. Whether due to welding heat deformation, workpiece misalignment, or clamping deviations, the system can correct these through real-time tracking and deviation correction, ensuring reliable welding quality.
Anti-Reflective Capability: The system effectively addresses detection errors caused by workpiece reflections, ensuring welding process stability.
Intelligent Control: The system features intelligent control algorithms that can automatically adjust the welding path based on welding parameters and environmental changes, improving welding quality and efficiency.
User-Friendly Interface: The system is equipped with an intuitive and user-friendly interface, allowing operators to easily set parameters and monitor operations.
Case
In the following case, it is clearly demonstrated how the system monitors and adjusts the seam in real time, with the welding torch always moving along the seam center. The welding process is smooth and efficient, and the weld seam is uniform with no visible defects.
ATINY's laser seam tracking system, through advanced laser technology and intelligent control algorithms, effectively addresses various challenges in welding water heater inner tanks. It automates and optimizes the welding process, enhancing welding quality and production efficiency while reducing production costs and operational complexity. With ongoing technological advancements, ATINY’s laser seam tracking system will continue to be optimized and improved, providing high-quality solutions for welding applications in more industries.
