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With the continuous development of the manufacturing industry, the demands for production efficiency and product quality are increasingly higher, especially in the pressure vessel industry. The welding process of gas cylinders requires extremely high weld seam quality and consistency while meeting strict safety standards. However, issues such as welding defects and low efficiency often arise from using automated blind welding equipment or manual welding. Today, let's explore the application of the ATINY seam tracking system in the automated welding of pressure vessel gas cylinders. Principle of Laser Seam Tracking System The laser seam tracking system uses laser sensors to collect the three-dimensional information of the weld seam. High-speed image processing algorithms analyze the position and shape of the weld seam in real-time. The system transfers the seam deviation data to the welding robot, which dynamically adjusts the welding gun trajectory based on the feedback, ensuring precise welding. Even in complex or changing environments, the system maintains stable performance. This closed-loop control process guarantees welding consistency and high quality while significantly reducing the need for human intervention. Challenges in Gas Cylinder Automated Welding The welding of gas cylinders faces the following main challenges: Large Errors: Workpiece size deviations and fixture clamping errors can cause inconsistencies or distortions in the weld seam position, resulting in welding deviations that affect seam consistency and quality. Low Production Efficiency: Currently, most gas cylinder welding processes rely on a rotary welding machine with an operator manually adjusting the welding gun position during the process. Poor Safety: The high labor intensity of workers, fatigue, or distraction can reduce consistency and stability. Additionally, cylinders with welding deviations are prone to explosions during pressure tests, which not only increase production costs but also pose a significant risk to operators’ safety. ATINY Solution To address these issues, the ATINY seam tracking system offers a comprehensive solution: High-Precisio

In modern industrial welding, achieving precise monitoring of the welding process and ensuring welding quality in high-intensity light environments has become a significant challenge for businesses seeking to enhance production efficiency and product quality. To address this issue, ATINY has introduced a specialized camera designed for welding applications—the Molten Pool Monitoring Camera. This camera is centered around molten pool monitoring, capturing dynamic changes during the welding process in real-time, thus providing robust support for intelligent management of welding operations. Main Functions of the Welding Strong Light Monitoring Camera Overcoming Strong Light Interference for High-Definition Monitoring The intense arc light and high-temperature spatter produced during welding create significant challenges for traditional cameras. The ATINY welding strong light monitoring camera employs High Dynamic Range (HDR) imaging technology and an anti-glare design to capture clear and stable images even under extreme lighting conditions, ensuring every welding detail is visible. Real-Time Monitoring of Molten Pool to Improve Welding Quality The morphology and dynamic changes of the molten pool directly determine welding quality. By monitoring the size, shape, and condition of the molten pool in real-time, the camera assists operators or welding robots in promptly adjusting parameters, preventing welding defects, and achieving higher quality and more consistent welds. Welding Process Recording and Analysis Beyond real-time monitoring, the ATINY molten pool monitoring camera features data recording capabilities for welding processes. By replaying and analyzing welding videos, manufacturers can quickly identify potential production issues and continuously optimize welding techniques and workflows. Remote Monitoring to Ensure Personnel Safety In hazardous or hard-to-reach environments, such as those involving high temperatures, high pressure, or toxic gases, traditional manual monitoring poses significant safety risks. The ATINY molten pool monitoring camera supports remote operation, allowing technicians to view real-time welding conditions fr

Narrow gap welding is an advanced technique that utilizes small welding gaps to improve welding efficiency and weld quality. Due to the limited space in the welding area, traditional monitoring methods often fail to meet the precision required for such operations. Therefore, employing efficient molten pool monitoring technology has become essential for enhancing productivity and ensuring welding quality in narrow gap welding. Challenges of Narrow Gap Welding The challenges of narrow gap welding are mainly reflected in the following aspects: Limited Field of View: The small welding area makes traditional monitoring methods (such as direct visual inspection) difficult to implement effectively, especially in automated production environments. Unstable Molten Pool: The stability of the molten pool is critical to weld quality. An excessively large or small molten pool can lead to weld defects, affecting the strength and appearance of the final product. Difficult Heat Input Control: The narrow weld width requires precise heat input control. Excessive heat can cause burn-through or cracks, while insufficient heat may result in incomplete welding. Efficient Monitoring of Narrow Gap Welding Processes To overcome the challenges of narrow gap welding, adopting efficient molten pool monitoring technology is crucial for improving welding quality and production efficiency. The ATINY molten pool monitoring camera plays a vital role in narrow gap welding. Its primary function is to monitor the molten pool state in real-time and analyze its changes using image processing technology, thereby optimizing the welding process. Advantages of the Molten Pool Monitoring Camera Real-Time Feedback and Adjustment The molten pool monitoring camera captures dynamic changes in the molten pool during the welding process, providing precise data on its state, shape, and size. This data enables the welding system to make real-time adjustments, ensuring the molten pool remains in optimal condition and guaranteeing weld quality. Reduced Human Intervention Automated molten pool monitoring systems reduce dependence on manual operations, enhancing production line efficiency

Electrical cabinets are essential infrastructure in modern industry and construction, and their quality and production efficiency are critical to the operation of the entire industrial chain. During the welding process of electrical cabinets, automated welding faces challenges due to seam misalignment, thermal deformation, complex structures, and mass production requirements. Today, let's explore the ATINY laser seam tracking sensor adaptive welding solution for electrical cabinets, which provides an efficient and stable automated solution for electrical cabinet welding. Principle of Laser Seam Tracker A laser seam tracker is a device based on laser vision sensor technology, and its working principle mainly includes: Laser Scanning: A laser beam is projected onto the workpiece surface, forming a clear light band or spot. Visual Recognition: The built-in sensor captures the relative position between the laser light band and the weld seam, analyzing the specific position and shape of the seam through real-time image processing. Deviation Correction: Based on the deviation between the weld seam position and the preset welding path, the system sends displacement compensation commands to the welding equipment to achieve precise welding. Data Feedback: The system monitors the state of the weld seam and welding quality in real-time, providing data support. The ATINY seam tracking system ensures high-precision welding, significantly reducing human intervention and improving automation. Challenges in Electrical Cabinet Welding Electrical cabinet welding has the following characteristics and challenges: Workpiece Placement Errors: Issues such as improper fixation, inaccurate clamping positions, and manufacturing errors can lead to misalignment of the seam, affecting welding quality. Thermal Deformation: High temperatures generated during welding can deform the metal, leading to seam deviation. High Welding Precision Requirements: The welding points in electrical cabinets need to carry certain electrical functions, and welding quality directly impacts performance. Large Production Volume, High Effici

With the rapid development of welding automation technology, the demand for welding quality and efficiency has also significantly increased. As an advanced molten pool observation tool, welding molten pool monitoring cameras play a crucial role in the welding process. Let’s explore the functions and advantages of welding molten pool monitoring cameras with ATINY. I. Functions of Welding Molten Pool Monitoring Cameras Real-time Monitoring of the Welding Process ATINY welding molten pool monitoring cameras use high-resolution vision sensors to capture the dynamic changes of the molten pool and monitor the weld formation process in real time. This real-time monitoring allows operators to intuitively understand the welding conditions and promptly adjust welding parameters in case of abnormalities. Welding Quality Analysis and Evaluation The shape and size of the molten pool are key parameters that directly affect weld quality. Monitoring cameras can continuously track these parameters, assess welding quality, and ensure compliance with required standards. Anomaly Detection and Alarm Defects such as welding misalignment, porosity, and cracks may occur during welding. Molten pool monitoring cameras can quickly detect such abnormalities and issue alarm signals, thereby preventing the production of defective parts. Data Recording and Traceability In addition to real-time monitoring, these cameras can record videos or images of the entire welding process, providing detailed data support for subsequent quality control. In case of quality issues, playback of recorded footage can help identify the root cause, ensuring full traceability. This feature is particularly suitable for industries with high welding quality requirements, such as automotive manufacturing, aerospace, and pressure vessel production. II. Advantages of Welding Molten Pool Monitoring Cameras Improved Welding Quality By precisely monitoring changes in the molten pool, these cameras help optimize welding process parameters and reduce human intervention, significantly enhancing weld quality and consistency. Reduced Production Costs The cameras minimize welding defects, redu

Six-axis welding robots are vital equipment in modern automated welding production and are widely used in various manufacturing industries, especially in automotive, shipbuilding, and machining. Installing the right welding fixtures is essential for achieving precise and efficient welding operations. This article, brought to you by ATINY laser seam tracking system experts, explains how to install welding fixtures for six-axis welding robots. 1. Choosing the Welding Fixture The selection of a welding fixture depends on the shape, size, and material of the workpiece. Welding fixtures should not only secure the workpiece firmly but also allow flexible operation of the robotic arm. Common types of welding fixtures include: Flat Fixtures: Suitable for simple flat welding tasks, often used for large, flat workpieces. 3D Fixtures: Designed to secure complex-shaped workpieces, ideal for three-dimensional or angled welding requirements. Custom Fixtures: Tailored for specific workpieces or welding tasks to improve precision and production efficiency. When selecting a welding fixture, consider the positioning accuracy of the workpiece and the stability of the fixture to prevent displacement or deformation during welding. 2. Preparation Before Fixture Installation Before installing the welding fixture, confirm the working range and workspace of the six-axis welding robot. Adjust the fixture's position and angle according to the workpiece size, fixture weight, and the robot's load capacity. Ensure the fixture's installation position provides sufficient space for the robot's operation to avoid interference or collisions. 3. Steps for Installing the Welding Fixture Securing the Fixture Base: Welding fixtures usually come with a base or mounting plate. Secure it firmly on the robot's worktable or base. Ensure the base is level to avoid fixture misalignment or tilting. Adjusting Fixture Position: Adjust the fixture's position based on the size and shape of the workpiece to enable precise securing. Use measuring tools (e.g., laser displacement sensors) to ensure the relative position between the fixture and the robot's en

With the advancement of welding automation, seam detection technology has become a critical aspect of welding quality control. While traditional seam detection methods have fulfilled production needs to some extent, increasing demands for precision and efficiency in industrial applications have made laser seam trackers a more competitive solution. Let's explore the comparison between laser seam trackers and traditional seam detection methods. Overview of Traditional Seam Detection Methods Traditional seam detection methods generally include the following: Visual Inspection: Advantages: Low equipment cost, simple operation. Disadvantages: Relies on human experience, low detection efficiency, unsuitable for complex seams or high-precision requirements. Mechanical Detection: Advantages: Simple structure, suitable for stable production environments. Disadvantages: Susceptible to surface roughness and welding fumes, limited sensitivity. The Technical Principle of Laser Seam Trackers ATINY laser seam trackers are advanced detection systems based on laser vision sensors, achieving seam tracking through the following steps: Laser Projection: A laser beam is projected onto the seam area, forming a specific spot or line. Visual Acquisition: High-precision sensors capture images of the reflected laser and analyze the seam's shape and position in real time. Data Processing: Algorithms calculate seam deviations and generate correction data for the welding path. Feedback Control: Correction data is transmitted to welding robots or specialized machines for real-time adjustment of the welding trajectory. Advantages of Laser Seam Trackers Compared to traditional seam detection methods, laser seam trackers offer the following significant advantages: High-Precision Detection Laser seam trackers accurately capture the three-dimensional information of seams, achieving sub-millimeter positioning accuracy. They are particularly suitable for complex seams and high-precision welding scenarios. Non-Contact Measurement The non-contact measurement of laser sensors eliminates mechanical wear and t

In-Depth Analysis of the Working Principles and Application Advantages of Laser Seam Trackers With advancements in technology, traditional manual welding methods are gradually being replaced by more advanced and precise automated welding techniques. In modern welding automation, laser seam trackers have become a highly efficient and precise welding aid, gaining increasing popularity among enterprises. Let’s explore the working principles and application advantages of laser seam trackers with ATINY. I. Working Principles of Laser Seam Trackers The core function of the ATINY laser seam tracker is to detect the position of the weld seam in real time and guide welding equipment to achieve precise welding. Its workflow generally includes the following key steps: Laser Scanning and Imaging The laser seam tracker projects a laser beam onto the surface of the workpiece, forming a clear laser line or spot. The position of the laser relative to the weld seam changes based on the seam’s shape and location. Visual Sensing and Data Acquisition High-precision sensors within the seam tracker capture real-time images of the laser line, generating two-dimensional or three-dimensional weld seam data. Intelligent Algorithm Analysis The built-in image processing algorithm analyzes the acquired weld seam data, extracting features such as position, width, and depth, and converts this data into command signals. Real-Time Adjustment of the Welding Path Based on real-time data from the seam tracker, welding robots or specialized welding machines adjust the welding torch's position and trajectory, ensuring the torch accurately follows the weld seam, thereby achieving high-precision welding operations. II. Application Advantages of Laser Seam Trackers Precise Positioning for Improved Welding Quality Laser seam trackers can detect even minute weld seam deviations, preventing issues caused by assembly errors or heat-induced distortion during welding. This significantly enhances welding quality. Reduced Manual Intervention and Increased Efficiency Traditional welding requires repeated manual teaching and adjustments. With ATINY laser seam t

Welding robots are essential tools in modern industrial automation, significantly enhancing welding quality and production efficiency with their flexibility and precision. The "six axes" design is a common structural feature of welding robots, giving them human-arm-like flexibility to handle complex welding tasks. What are the functions of each axis in a welding robot? This article provides a detailed explanation. Axis 1: Base Rotation Axis Axis 1 connects the robot to the ground and allows the base to rotate. Its primary function is to enable the robotic arm to swing left and right, expanding the working range. This functionality is the foundation for completing complex welding paths. Axis 2: Shoulder Swing Axis Axis 2 controls the up-and-down motion of the robotic arm, often referred to as the "upper arm swing axis." By adjusting the height of the arm, the robot can accommodate workpieces of varying heights, achieving precise vertical positioning. Axis 3: Elbow Swing Axis Axis 3 governs the forward and backward swing of the robotic arm. Working in coordination with Axis 2, it ensures accurate movement of the welding torch in the forward and backward directions, making it critical for welding in deep or confined areas. Axis 4: Wrist Rotation Axis Axis 4 is the wrist rotation axis, responsible for adjusting the lateral angle of the welding torch. It allows the torch to rotate to specific positions, meeting the requirements of different welding angles, especially for curved or intricate weld seams. Axis 5: Wrist Bend Axis Axis 5 controls the up-and-down bending motion of the wrist. By adjusting this axis, the welding torch can reach more complex positions, effectively addressing welding tasks in spatially constrained areas, such as executing precise welds in narrow gaps. Axis 6: Wrist Swing Axis Axis 6 manages the lateral swing (horizontal deflection) of the wrist. Positioned between Axis 5 and the robot’s end effector, this axis enables 360° horizontal rotation, allowing the welding torch to flexibly adjust its orientation to maintain the correct angle with the weld seam throughout the welding process. App