Laser Seam Tracking Principle:
Laser seam tracking technology employs a laser beam to illuminate the workpiece surface, while a sensor captures the reflected light to detect the weld's position and shape. The sensor's high-speed camera and image processing system capture real-time weld images and analyze them using algorithms to determine the weld's precise location and trajectory. Guided by this information, the sensor instructs the welding equipment to automatically adjust welding parameters and paths, enabling accurate weld tracking and automated welding.
Laser seam tracking boasts high resolution, high precision, and real-time performance, adapting to welds of various materials and complex shapes. Compared to traditional vision recognition and contact tracking methods, laser seam tracking excels in both speed and accuracy.
Challenges in Automated Welding of Storage Tanks:
Storage tanks, as high-pressure containers, demand stringent welding quality standards. The primary challenges in storage tank welding include:
Complex and Varying Welds: Storage tanks, typically cylindrical or spherical, feature intricate weld shapes and long weld paths. Equipment blind welding struggles to ensure weld consistency and stability.
High Welding Position Accuracy: Withstanding high internal pressure, storage tanks require completely sealed welds. Even minute welding defects pose severe safety hazards.
Environmental Impact: The high temperatures, fumes, and reflected light generated during welding often compromise weld quality and the welder's line of sight.
High Labor Costs: Manual welding necessitates skilled workers, high labor intensity, and low production efficiency.
CR Solution:
CR Laser Seam Tracking Sensor provides a comprehensive solution for automated welding of storage tanks. The system comprises a laser sensor, data processing unit, and welding control system, achieving precise welding through real-time weld tracking via laser scanning.
High-Precision Laser Sensor: The sensor accurately captures the weld's three-dimensional information, adjusting the welding path in real-time to ensure the weld and welding gun remain in optimal positions.
Intelligent Data Processing: The high-speed processing unit rapidly analyzes laser scan data, generating an accurate weld model, and providing real-time feedback to the control system.
Automated Control System: Interconnected with welding equipment, the control system automatically adjusts the welding trajectory based on weld tracking data, ensuring consistent weld quality.
Case Study:
In a storage tank manufacturing plant, traditional manual welding methods yielded inconsistent weld quality due to complex welds and difficult position control, resulting in low production efficiency. Implementing the laser seam tracking system enabled the welding equipment to track the weld path in real-time, precisely controlling the welding process.
Furthermore, the sensor's robust anti-interference capabilities ensured stable operation under harsh environments, maintaining the welding process's continuity and stability.
The application of laser seam tracking sensors in automated storage tank welding highlights the advantages of high precision, intelligence, and automation. It not only enhances weld quality and production efficiency but also significantly reduces labor costs and safety risks. As technology advances, laser seam tracking technology will find broader applications in various industrial sectors, driving the continuous development of China's manufacturing industry.
Note:
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