ATINY Laser Seam Tracking for Smart Welding of Bevel Joints in Ultra-High Voltage Transformers

With the rapid development of the power industry, the production requirements for ultra-high voltage transformer instrumentation are increasingly demanding, especially in terms of welding quality and efficiency. Traditional welding methods often struggle to ensure high precision and consistency when dealing with complex bevel joint seams, leading to low production efficiency and defects. To improve welding quality and automation levels, the introduction of ATINY's laser seam tracking technology provides a reliable solution to this challenge.

Laser Seam Tracking System Principle

The laser seam tracking system uses high-precision laser sensors to detect changes in the weld seam position during the welding process in real-time. Based on the real-time feedback, it automatically adjusts the position and orientation of the welding equipment. The core of the system lies in the integration of laser sensors and control algorithms, enabling precise seam positioning and real-time tracking during the welding process, thus ensuring welding quality and efficiency.

Laser Seam Tracking Technology Typically Involves the Following Steps:

1. Seam Identification: The laser sensor acquires information such as the weld seam's profile by reflecting the laser beam.
2. Real-Time Tracking: During welding, the system continuously monitors the position of the weld seam and makes real-time adjustments.
3. Feedback Control: Based on sensor data, the control system adjusts the robot or welding equipment’s parameters in real-time to ensure precise seam alignment.

With ATINY's seam tracking technology, manual errors and equipment deviations in traditional welding are greatly reduced, leading to significant improvements in welding precision and efficiency.

Challenges in Automated Welding of Bevel Joint Seams in Ultra-High Voltage Transformer Instrumentation

Ultra-high voltage transformers are critical components in power systems, serving to convert voltage signals from the high-voltage side to the low-voltage side. Due to the high precision required, the welding process for transformers must be tightly controlled. However, the bevel joint seams in ultra-high voltage transformers are often complex and technically demanding, presenting the following challenges:

1. Complex Bevel Shape: The bevels on transformers often have special shapes and large sizes, making seam tracking and positioning difficult.
2. High Precision Requirements: The welding process must ensure extremely high precision, as even the smallest deviation can cause equipment malfunctions or safety hazards.
3. Low Production Efficiency: Traditional welding methods rely on manual labor, which is prone to errors and leads to low production efficiency.
4. Insufficient Automation: Traditional welding equipment struggles with highly complex welding tasks, often requiring manual intervention and repeated adjustments.

These challenges result in high production costs, long production cycles, and difficulty in maintaining consistent product quality. Therefore, achieving high-precision, intelligent, and automated welding for bevel joint seams is a critical issue in this industry.

ATINY Solution

To address the challenges of welding bevel joint seams in ultra-high voltage transformer instrumentation, ATINY has introduced an intelligent welding solution based on laser seam tracking technology. This solution employs multi-point seam positioning technology to achieve automation, precise control, and efficient production during the welding process.

Multi-point seam positioning technology is an essential application within ATINY's laser seam tracking system. The technology uses laser sensors to monitor multiple points on the workpiece’s weld seam and quickly locate its position. The system operates as follows:

1. Laser Scanning: High-precision laser sensors scan the weld seam on the workpiece to obtain its profile shape.
2. Multi-Point Positioning: By monitoring multiple points on the workpiece, the system analyzes seam deviations in real time using high-speed data processing algorithms, accurately locating the weld seam.
3. Control System: The seam's position and shape information is transmitted to the control system in real time.
4. Automatic Adjustment of Welding Path: Based on feedback data, the welding equipment automatically adjusts its position and orientation to ensure the weld is made at the correct location, preventing welding deviations.

Application Case

In a certain ultra-high voltage transformer instrumentation production project, ATINY's laser seam tracking system was successfully applied to intelligent welding of bevel joint seams. The bevel shape of the transformer was complex, and controlling the welding position was difficult. By using ATINY's laser seam tracking system, the welding process was precisely controlled, resulting in a significant increase in production efficiency and stable welding quality, meeting the high precision requirements.

With the continuous development of intelligent manufacturing and automation technologies, laser seam tracking technology will further drive the smart manufacturing of high-precision products, such as ultra-high voltage transformer instrumentation, enhancing production efficiency and product quality in the entire power industry. ATINY will continue to innovate and apply laser technology, helping customers achieve more efficient and precise production goals.