Principle of Laser Seam Tracking
The laser seam tracking sensor uses laser scanning and image processing technology to detect the weld seam position in real-time. The laser beam emitted by the sensor forms a spot on the surface of the welding piece, and a high-speed camera captures the image of the spot. Image processing algorithms are then used to extract the specific position and shape of the weld seam. Subsequently, the sensor transmits this information to the welding control system, which adjusts the welding torch's trajectory in real-time based on the weld seam position, ensuring precise tracking of the weld seam during the welding process.
The key to laser seam tracking lies in the sensor's high sensitivity and quick response capability, allowing it to handle changes in weld seam positions under complex conditions, thereby ensuring the stability and consistency of welding quality.
Challenges in Welding Automotive Air Deflectors
As an important component of the automotive cooling system, the welding quality of air deflectors directly affects the heat dissipation performance and overall efficiency of the engine. However, air deflectors are usually composed of irregularly shaped metal sheets, and the weld seams of the workpieces are inconsistent. Errors in assembly, fixtures, and material cutting necessitate repeated teaching, resulting in low welding efficiency and quality. Most existing automated welding equipment relies on fixed trajectories, making them poorly adaptable to workpieces with complex shapes and unable to meet high-quality welding requirements.
ATINY's Solution
To address these welding challenges, ATINY has introduced an automated welding solution based on the laser seam tracking sensor. This solution achieves high-precision, high-efficiency welding of air deflectors by detecting the weld seam position in real-time and intelligently adjusting the welding trajectory.
High-precision Seam Tracking: The sensor uses laser scanning technology to detect the weld seam position in real-time, ensuring that the welding torch is always accurately aligned with the weld seam, significantly improving welding precision.
Increased Welding Efficiency: By utilizing automated welding equipment, manual operations are reduced, production efficiency is increased, and dependence on operator skill levels is minimized.
Adaptability to Complex Conditions: Whether dealing with workpieces of complex shapes or varying weld seam positions, the sensor can quickly respond and make adjustments, ensuring the stability of welding quality.
Application Case
In an automotive parts manufacturing plant, traditional welding methods were not only inefficient but also produced inconsistent quality. After introducing the ATINY laser seam tracking sensor system, the welding equipment could track the weld seam path in real-time and precisely control the welding process. This led to a significant improvement in welding quality, with uniform and aesthetically pleasing weld seams, and no instances of missed or weak welds, thereby markedly increasing the product pass rate.
With ongoing technological advancements and expanding applications, the ATINY laser seam tracking sensor is expected to play an increasingly important role in various fields, driving the manufacturing industry towards greater intelligence and efficiency. ATINY remains committed to technological innovation, providing customers with superior automated welding solutions.
