Shipbuilding demands extremely high welding quality and efficiency. Traditional welding methods rely on manual adjustments or pre-programmed robotic welding, which struggle to accommodate workpiece positioning errors, assembly deviations, and complex weld trajectories. Weld Navigator’s laser seam tracking sensor, with its high-precision real-time seam tracking technology, provides a more intelligent and stable solution for the shipbuilding industry. Let’s explore how laser seam tracking sensors enhance shipbuilding welding automation.
Principle of Laser Seam Tracking Sensors
Laser seam tracking sensors are based on laser vision sensing technology. By scanning the weld seam surface with a high-precision laser beam, they capture the three-dimensional contour of the seam in real time. The internal algorithm analyzes the weld position, shape, and gap, then transmits the data to welding robots or automated welding equipment. This enables automatic seam tracking and dynamic torch position adjustment, ensuring welding quality consistency.
Challenges in Shipbuilding Welding Automation
During ship construction, the complexity of welding processes presents several challenges for automation:
- Significant weld seam deviation: Due to steel plate processing and assembly errors, the weld seam often deviates from the preset path. Traditional robots require frequent teaching, leading to inefficiency.
- Diverse weld seam types: Various weld types, including butt joints, fillet welds, and T-joints, require welding equipment to handle multiple seam configurations.
- Large workpieces: Ship structures are massive, with weld seams extending several meters or even tens of meters. Manual welding is labor-intensive and struggles to maintain long-term consistency in quality.
- High interference levels: Shipbuilding workshops contain welding fumes and variable lighting conditions that affect standard sensors, reducing detection accuracy.
Weld Navigator’s Solution
To address these challenges, Weld Navigator’s laser seam tracking sensor provides a comprehensive solution with the following key advantages:
- Seam tracking: Real-time detection of weld seam positions and automatic torch path adjustment to accommodate deviations.
- Support for multiple weld types: Capable of tracking straight seams, fillet welds, T-joints, and more, meeting diverse structural requirements.
- High-precision positioning: Advanced laser vision algorithms enable accurate seam tracking even with slight deformation or positional changes.
- Interference resistance: Designed to counteract welding fumes and strong light interference, ensuring stable seam recognition in harsh environments.
- Non-contact measurement: The non-contact sensing method prevents sensor wear, enhancing durability and reducing maintenance costs.
Application Case: Automated Welding of H-Beams in Shipbuilding
In an automated H-beam welding project at a major shipyard, assembly errors caused significant weld seam deviation. Traditional automation required repeated manual teaching and resulted in inconsistent weld paths that failed to meet high-quality standards. By integrating Weld Navigator’s laser seam tracker into existing automated welding equipment, the system achieved real-time seam detection and tracking, dynamically adjusting the welding torch position to ensure uniform multi-layer welding.
Conclusion
Upgrading shipbuilding welding automation requires high-precision seam tracking technology. Weld Navigator’s laser seam tracking sensor, utilizing laser scanning for seam identification and real-time tracking, helps shipbuilding enterprises overcome welding deviations and workpiece deformation issues. This technology enhances welding quality, efficiency, and stability, driving the industry toward intelligent and flexible automation. As technology advances, China’s manufacturing sector will continue progressing toward higher levels of automation and intelligence.
