The Weld Navigator laser weld seam tracking sensor adopts a laser triangulation principle, where the laser beam is expanded to form a laser line projected onto the surface of the object being measured. The reflected light passes through a high-quality optical system and is projected onto an imaging matrix. The sensor calculates the distance (Z-axis) and position information along the laser line (X-axis). By moving the measured object or probe, a set of three-dimensional measurement values is obtained. This information can be used for seam search and positioning, seam tracking, adaptive welding parameter control, seam formation inspection, and real-time transmission to robotic units, completing various complex welds, avoiding quality deviations, and enabling unmanned welding.
Components and Functions of the Weld Seam Tracking Sensor
The Weld Navigator seam tracking sensor mainly consists of a CCD camera, a semiconductor laser, a laser protection lens, a splash guard, and a wind cooling system. Using optical propagation and imaging principles, it obtains the position information of each point within the laser scanning area, and through complex algorithms, it performs online real-time detection of common weld seams. The sensor is typically installed at a preset distance (ahead) from the welding gun, allowing it to observe the distance from the sensor body to the workpiece, meaning the installation height depends on the sensor model. When the welding gun is correctly positioned above the seam, the camera can observe the weld seam.
CCD Camera
The main function of the CCD camera in the seam tracking sensor is to capture images. When photographing an object, the reflected light from the object passes through the camera's lens and is transmitted to the CCD. After exposure, the photodiodes are excited by the light, releasing charge, and the electrical signal is generated. The CCD controller controls the current generated by the photodiodes through a signal line, and the camera collects this signal and sends it to an amplifier. After amplification and filtering, the signal is sent to an A/D converter to be converted from an analog to a digital signal. The numerical values represent image data. These values are then processed in a Digital Signal Processor (DSP) for color correction, white balance, and other post-processing. After encoding, the image is stored in the camera's memory (either internal or external storage).
Semiconductor Laser
The semiconductor laser generates power through a linear generator, producing a uniform density, high straightness, and stable laser output in a linear form. The laser is available in red and blue light and can be customized to different wavelengths, angles, and line widths based on customer requirements.
Optical Protection Lens
Since smoke and spatter are generated during the welding process, they can affect data collection. Therefore, each sensor is equipped with an optical protection lens. This lens serves two purposes: protecting the laser and camera and filtering light. If the lens becomes dirty, it should be replaced promptly. Any dirt, such as fingerprints or oil drops, will increase the absorption rate of the lens, reducing its lifespan.
Splash Guard
This part is used to block interference from arc light, spatter, and smoke, ensuring that the sensor system operates more precisely and stably.
Wind Cooling System
Given the high temperatures during welding, most systems use wind cooling to both cool the sensor and extend its lifespan. The sensor housing is rated IP67 and operates within a temperature range of 5°C to 45°C. Temperatures exceeding this range may impact the sensor’s lifespan. If necessary, an additional water-cooling mounting plate can be used for cooling the sensor head.
The sensor uses complex algorithms to perform real-time detection of common weld seams. It has settings for the detection range, capabilities, and solutions to common welding problems. The device calculates the deviation between the detected seam and the welding gun, outputs the deviation data, and the motion actuator corrects the deviation in real time, precisely guiding the welding gun for automatic welding, thus achieving intelligent real-time tracking of the seam during the welding process.
Weld Navigator Laser Weld Seam Tracking: A Major Innovation
For welding, Weld Navigator laser seam tracking represents a significant invention. With the development of advanced manufacturing technology, the automation and intelligence of welding tracking have become inevitable trends. In the coming years, Creations Intelligent Control’s laser weld seam tracking will not only need technological upgrades but also, by deeply understanding customer applications, expand its usage and improve products to meet user needs.
