With the continuous development of the manufacturing industry, the demands for production efficiency and product quality are increasingly higher, especially in the pressure vessel industry. The welding process of gas cylinders requires extremely high weld seam quality and consistency while meeting strict safety standards. However, issues such as welding defects and low efficiency often arise from using automated blind welding equipment or manual welding. Today, let's explore the application of the ATINY seam tracking system in the automated welding of pressure vessel gas cylinders.
Principle of Laser Seam Tracking System
The laser seam tracking system uses laser sensors to collect the three-dimensional information of the weld seam. High-speed image processing algorithms analyze the position and shape of the weld seam in real-time. The system transfers the seam deviation data to the welding robot, which dynamically adjusts the welding gun trajectory based on the feedback, ensuring precise welding. Even in complex or changing environments, the system maintains stable performance. This closed-loop control process guarantees welding consistency and high quality while significantly reducing the need for human intervention.
Challenges in Gas Cylinder Automated Welding
The welding of gas cylinders faces the following main challenges:
- Large Errors: Workpiece size deviations and fixture clamping errors can cause inconsistencies or distortions in the weld seam position, resulting in welding deviations that affect seam consistency and quality.
- Low Production Efficiency: Currently, most gas cylinder welding processes rely on a rotary welding machine with an operator manually adjusting the welding gun position during the process.
- Poor Safety: The high labor intensity of workers, fatigue, or distraction can reduce consistency and stability. Additionally, cylinders with welding deviations are prone to explosions during pressure tests, which not only increase production costs but also pose a significant risk to operators’ safety.
ATINY Solution
To address these issues, the ATINY seam tracking system offers a comprehensive solution:
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High-Precision Laser Tracking:
The system uses advanced laser sensors to monitor the weld seam position in real-time, ensuring precise welding for each pass and improving weld quality and consistency. -
Dynamic Trajectory Adjustment:
The system automatically adjusts the welding gun trajectory based on real-time data feedback, ensuring that the best welding position is maintained throughout the process. -
Seamless Integration:
The laser seam tracking system can be retrofitted onto existing welding equipment, reducing the cost of equipment modification. -
Intelligent User Interface:
The system is equipped with an intuitive human-machine interface, simplifying operation, reducing worker training costs, and improving work efficiency.
Application Case
A large gas cylinder manufacturing enterprise implemented the ATINY seam tracking system, resulting in a comprehensive upgrade of their production line. The company significantly reduced welding defects while meeting high-capacity production demands. By reducing human involvement and rework rates, they effectively lowered production costs, enhanced welding automation, and minimized safety risks associated with manual operations, all while adhering to the stringent industry standards for pressure vessels.
The ATINY seam tracking system, with its high-precision laser detection and intelligent dynamic seam adjustment, provides a comprehensive solution for the automated welding of gas cylinders. It not only solves the technical challenges of traditional welding but also significantly enhances production efficiency and product quality. In the future, ATINY will continue to optimize its technology to support the automated welding needs of more industries.
