All Article

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 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

As the automotive manufacturing industry gradually shifts toward automation and intelligence, welding remains a crucial process for vehicle bodies, components, and axles. Welding precision and efficiency directly impact production costs and product quality. Traditional welding methods mainly rely on manual operations, which are often limited by workpiece assembly errors and complex weld seams. The introduction of laser weld seam tracking systems has significantly improved welding precision, reduced manual intervention, and provided an effective solution for the automotive manufacturing industry. Let's explore some application cases of weld seam tracking systems in this sector. Principle of Weld Seam Tracking Systems Weld seam tracking systems rely mainly on laser sensors or vision sensors. These sensors scan the weld seam profile in real-time, extracting features such as weld seam position, shape, and groove width through image processing algorithms. The data is then transmitted to welding robots or automated welding equipment for path adjustment. This system can automatically compensate for workpiece deformation, assembly errors, and welding deviations, ensuring precise alignment between the weld seam and the welding torch, thereby improving welding consistency. Industry Welding Challenges In the automotive manufacturing industry, welding processes face several significant challenges: Workpiece Tolerance and Assembly Deviation: During body part manufacturing, precision cannot always be guaranteed. Workpiece and assembly tolerances can cause weld seam displacement. Welding Deformation: Heat input during welding can cause metal deformation. Traditional programmed robots cannot adapt to dynamic changes, resulting in welding defects. High Efficiency Requirements: Automotive production lines demand high welding efficiency. Traditional programmed robots often require repeated teaching, making it difficult to meet production demands. Consistency: Long hours of manual welding can lead to fatigue, reducing stability and making it difficult to maintain consistent weld quality. Weld Navigator Solution Weld Navigator’s weld seam tracking syste

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 se

In modern industrial manufacturing, welding is an essential process, where ensuring weld quality and consistency is a critical requirement. However, in complex working conditions, challenges such as assembly errors and welding-induced thermal deformation often cause the weld seam to deviate from its intended path. The Weld Navigator seam tracking system is developed to address these challenges. This tracking system can correct weld deviations in real-time under complex conditions, ensuring weld quality and consistency. Working Principle of Laser Seam Tracker The core technology of a laser seam tracker is based on the laser triangulation method. The seam tracking system installs an optical sensor or camera in front of the welding position, using a laser beam to illuminate the weld seam area. The sensor captures the reflected laser signals from the weld seam and generates three-dimensional contour data. Then, image processing techniques such as edge detection and template matching are used to identify the weld seam’s position and shape. Finally, the seam tracker transmits this information to the welding robot, which utilizes an adaptive fuzzy control algorithm to correct its trajectory in real time, achieving precise weld seam tracking. Real-Time Path Correction In complex conditions, weld seams may undergo irregular variations, making pre-set welding paths unsuitable for actual needs. The Weld Navigator laser seam tracker achieves real-time path correction through the following methods: Laser Scanning: The laser seam tracker can scan and acquire weld seam information within milliseconds. Real-Time Monitoring: Sensors combined with image processing algorithms monitor weld seam position and shape variations. Data Processing: By processing and analyzing the data, the system determines the actual weld seam position and deviations. Path Adjustment: Based on system analysis results, control signals are generated to adjust the welding robot’s path and orientation in real time, ensuring precise welding. Integration of Control Algorithms To achieve precise real-time path correction, the laser seam tracker employs multiple control algorithms, in

The development of the industrial era has accelerated the pace of welding automation, bringing welding robots to the forefront. However, it's still too early for welding robots to completely replace manual welding in the technical field. Achieving the goal of welding robots replacing 90% of manual welding labor in batch production is still attainable. Welding robots are favored by many small and medium-sized enterprises due to their high efficiency, high quality, and ease of management. However, when it comes to welding high-precision workpieces, welding robots can sometimes fall short. This is where the Weld Navigator seam tracking system comes into play, enabling automated seam tracking for high-precision welding on top of the existing robot setup. Why Add a Seam Tracking System to a Welding Robot? Welding robots often encounter technical issues during the welding process, such as workpiece clamping deviations and thermal distortion of sheet metal parts. The practical needs of users: Many users weld a variety of workpieces with small production batches, which requires high precision and skilled welding technicians. This often necessitates reprogramming or teaching the robot for each different workpiece, prolonging the welding cycle. The high cost of improving workpiece feed systems: Updating existing processing equipment and designing and purchasing high-precision fixtures can be expensive. Welding robots often require manual rework after welding, which leads to high labor costs and a high rework rate. For small and medium-sized enterprises struggling to survive, this is a significant challenge. Therefore, in response to the practical production needs, improving welding robot efficiency, reducing work time and complexity, and enhancing weld quality all require the timely addition of the Weld Navigator seam tracking system.

The seam tracker is a great invention for welding, and the Weld Navigator seam tracker can be perfectly adapted to both specialized machines and robots, meeting the welding needs in many environments. With the continuous development of domestic manufacturing over the years and the ongoing technological research, welding automation and intelligence have become key directions for the future. The realization of automated welding not only improves production efficiency and product quality, but also liberates workers from strenuous physical labor, avoiding various safety risks. In the coming years, Weld Navigator's laser seam tracking technology will continue to evolve and update. In actual applications, we will also continuously explore and deepen collaboration with clients to meet user needs and improve product quality. What Types of Welding Can a Seam Tracker Be Used For? Corner Weldments: With the accumulation of core algorithms, the tracker has strong adaptability. Even when the workpiece cross-section is irregular, and there are welding spot interferences in the weld, it can reliably identify seams at 90-degree, 45-degree, and arbitrary angles. Circular Workpieces: For ring welding, butt welding, spiral welding, pressure vessels, spiral pipes, and other circular workpieces, the tracker can reliably identify seams. Butt Joint Workpieces: For welding various combinations of welding processes on two plates, it supports normal steel plates, stainless steel plates, and high-reflection materials, and can reliably identify seams. Box-Type Workpieces: By accurately calculating the spatial position of the welding torch through core algorithms, the tracker can handle standard rectangular workpieces, polygonal workpieces, and various workpiece shapes without limitations. It can reliably identify seams in both flat welds and vertical welds. These are the common welding types where a seam tracker is applied. In addition, Weld Navigator can also customize the seam tracking system according to the specific needs of manufacturing enterprises, helping companies achieve automation and intelligence transformation in welding.

With the continuous advancement of automation in the manufacturing industry, welding robots have become an integral part of production lines across many sectors. Especially for complex welding tasks, integrated visual tracking systems can significantly enhance welding accuracy and efficiency, reduce manual intervention, and meet more demanding production requirements. Today, let’s explore the five core technological elements of integrated visual tracking systems in welding robots to help you better understand and select the right welding automation solutions. High-Precision Laser Sensing Technology Laser sensors are one of the core components of the welding robot’s visual tracking system. By utilizing laser distance measurement technology, the system can accurately detect the real-time position and changes of the weld seam, ensuring high-precision control during the welding process. The Weld Navigator laser sensor is equipped with anti-interference capabilities, allowing it to adapt to harsh working conditions such as high temperatures, smoke, and bright lights, ensuring the system remains stable and reliable in complex environments. Visual Image Processing and Algorithm Optimization Welding robots need to capture images of the weld seam through visual sensors and analyze them in real time using image processing algorithms. This process includes precise recognition of the weld seam's position, shape, and orientation, which allows the robot to adjust its path planning and welding angles. The core of Weld Navigator’s image processing technology lies in its efficient algorithm optimization, enabling the system to process large amounts of data in dynamic, real-time production environments, making quick and accurate decisions. Real-Time Dynamic Tracking and Control Real-time dynamic tracking refers to the system’s ability to continuously track weld seam changes during the welding process and quickly send feedback to the robot for position adjustment. This technology requires the system to have extremely fast response speeds and data transmission capabilities, ensuring that the robot can immediately adapt to weld seam chang

Today, domestic manufacturing in China has become very mature. After years of rapid development, the domestic market now demands higher precision and efficiency in welded components. However, many welders face limitations due to technical skill and fatigue, leading to welding that does not meet standards. Additionally, welding generates sparks, splatter, and smoke, all of which pose health risks to workers. With advancements in technology and rising production demands, automation has been naturally accelerated. Today, automation and intelligent technologies are increasingly applied in the welding field, making welding seam tracking systems a key focus in welding automation research. Precise and efficient Weld Navigator seam tracking can quickly locate the weld seam accurately and ensure weld quality, marking a critical direction in welding automation. Laser seam tracking technology addresses problems like missed welds and weld misalignment in laser welding applications. By integrating a laser seam tracking system with industrial robots or specialized welding machines, it automatically detects and adjusts the position of the welding torch during the welding process, maintaining a constant distance between the torch and the workpiece. This ensures weld quality, increases welding efficiency, and reduces labor intensity. It also solves issues like weld quality caused by workpiece thermal deformation or inconsistency, and frees welders from hazardous environments, preventing physical harm. With the current market’s urgent demands, Weld Navigator's self-developed laser seam tracking system can truly achieve welding automation. By integrating the seam tracking system with automated equipment, it offers a comprehensive solution that improves weld quality and efficiency while reducing the physical strain on welders. Weld Navigator's laser seam tracking system, developed in-house with multiple patents, utilizes complex algorithmic programs for online real-time seam detection. It tracks without contact, using sensors to measure seam offset and guide the welding torch to the correct position. The system offers aesthetically pleasing weld formation, reliable qualit

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