Introduction
Corrugated plates, also known as profiled sheets, are materials formed into various wave shapes through mechanical processing. Compared to other sheet types of the same thickness, corrugated plates boast 10 to 30 times greater strength. As a result, industries with strict weight requirements, such as aerospace, shipbuilding, containers, truck bodies, and highway barriers, have significantly increased their use of corrugated plates. This rising demand has naturally accelerated the need for automated welding solutions for corrugated plates.
Challenges in Corrugated Plate Welding
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Data Collection Challenges
In automated welding applications, data collection and mechanical process optimization remain difficult challenges for current mechanical automation technology. Since data extraction is key to achieving automation, the collection and organization of this data should be a top priority. -
Numerous Variables Affect Welding Quality
Despite automation, robotic welding systems still face various variables that impact welding quality. Factors such as welding process selection, positioning, and distortion management during welding contribute to these complexities. Reducing these variable factors remains challenging.
Weld Navigator Laser Displacement Sensor Solution
Weld Navigator's self-developed laser displacement sensor integrates a high-speed signal processor and intelligent processing software, offering a portable, integrated smart solution for displacement measurement. The sensor employs a cylindrical lens that expands the laser beam into a line shape. The laser scatters on the target object, and the reflected light forms an image on the CMOS sensor. By detecting changes in position and shape, the system measures displacement and dimensions.
The sensor supports 74 measurement modes, making it highly versatile. It can perform 2D measurements such as height, height differences, width, position, shape, cross-section, warpage, flatness, angles, radii, and casing thickness. It also supports 3D measurements for applications like solder bridge detection, volume detection, welded plate seam inspection, and wood diameter measurement.
By using the laser displacement sensor to collect real-time weld seam position data, the system transfers this data to an industrial PC, which processes and sends the real-time weld seam position feedback to a PLC. This feedback ensures the welding torch follows the correct path with precision. Acting as both the "eyes" and "brain" of the welding system, the sensor enables 24/7 real-time weld seam detection, ensuring the welding torch maintains accurate positioning.
With its high precision, cost-efficiency, simple setup, and user-friendly operation, the Weld Navigator laser displacement sensor is ideal for integration into existing robotic and automated systems.
Weld Navigator’s Commitment to Innovation
With over a decade of experience, Weld Navigator has consistently focused on developing advanced machine vision solutions. Our extensive expertise in intelligent welding solutions and comprehensive welding data ensures our laser displacement sensors deliver industry-leading performance. These sensors are poised to replace human vision and cognitive judgment in repetitive welding tasks, driving higher quality standards in intelligent welding systems.
