Perfectly welding a joint is a skill that takes years of training by professional welders to perfect. Automating this function is possible, but you’ll need to evaluate the different approaches, methodologies, and associated technologies before committing to a solution. To help you grapple with the latest capabilities, here’s everything you need to know about welding seam tracking.
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Seam tracking or weld joint tracking uses an automated system that provides real-time sensing and adaptive control while executing a robotic welding operation. Different solutions are available on the market that enable automated welding operations to track the welding seam in real-time and control the process using 3D lasers, cameras, slides, controllers, and teach pendants.
Choosing the right technology depends on your current welding workflow requirements, as these systems can control the voltage, travel speed, wire feed, and weld bead formation.
Seam tracking systems vary between suppliers and integrators but use the same base technologies to achieve the required control function. Vision and sensing solutions provide high-quality, industrially proven seam tracking, welding inspection, and precise process control in a single operation.
(source: Binzel Abicor)
The different welding seam tracking technologies are:
Automating the tracking of weld seam in a robotic process isn’t easy. Each workpiece, fixture, and welding system needs to operate in conjunction to maintain the integrity of every joint. In addition, adopting these solutions adds complexity to the operation, requiring extensive engineering to perfect.
Implementing these solutions will require:
For those reasons, you should look at automating your welding operations without weld seam tracking systems. With a good fixture design or repeatable jigs, you can remove the need for adding complex technologies to your weld cells.
Welding cobots are redefining the capabilities available to SMEs that deal with high-mix, low-volume orders. It provides consistent, repeatable results by combining easy programming, accurate execution, and proven reliability.
Welding cobots let you set up the weld operation, oversee the process, and interact with the work cell. Cobot welding systems do not need weld seam tracking to weld your part repeatably and provide great ROI. In fact, not needing through arc seam tracking with your cobot helps to reduce complexity and decrease the cost of ownership of the welding cell.
Welding cobots are generally easier to program than traditional welding robots, allowing you to get into production quickly without relying on complex programming skills. These welding cobot tools will enable you to empower your welders to operate them without previous robotics knowledge. They are great solutions to fill your need for welders.
So deciding to add complexity to the system would then defeat the goal of automating with simple-to-use solutions.
When looking to add automation to welding operations, collaborative welding robots do not need expensive, complex weld seam tracking solutions to produce quality welds.
Here are a few reasons why welding cobots don’t need seam tracking technologies:
A welding cobot is already providing a simple solution to automate your welding operations and solve your need for extra welders. They only require the operator, which can be your welder, to set up the weld workflow once and only intervene if something goes wrong. To conclude, you don’t need to add complex seam tracking technologies to get productivity and ROI from those cobots.
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Welding seam tracking systems require complex technology and diligent maintenance. On the contrary, a welding cobot reduces the complexity of automation and keeps operators in control of each weld workflow. So, you won’t need expensive programmers. Instead, you’ll be able to start production quickly and empower your current welders to operate the robots. Then, with automated and repeatable results, you can increase your throughput, reduce your cycle times, and ensure consistent quality welds for each high-mix, low-volume job you accept.
Precise positioning depends on laser
The accuracy of laser welding relies heavily on the precise positioning of the laser beam. Seam tracking systems in laser welding machines play a vital role in achieving this precision. By utilizing advanced sensing technology, the system can continuously track and adjust the position of the laser as it moves along the seam to be welded. This ensures minimal deviation when the laser is fired. As a result, manufacturers can achieve consistent and precise welds that guarantee the quality of the final product.
Good quality and low price
When choosing a laser welding machine, customers often worry about spending too much money. However, with a seam tracking system, they don't have to sacrifice quality to stay within budget. By precisely positioning the laser beam, the seam tracking system ensures that every weld is of high quality and meets the required standards. This eliminates the need for costly rework and reduces the manufacturer's overall expense. The combination of good quality and low price makes a laser welding machine with seam tracking an excellent investment for any production facility.
Application advantage
In addition to increased accuracy and cost-effectiveness, seam tracking systems bring significant advantages to the welding process. For example, it can realize the intelligent adjustment of the welding system, thereby greatly improving production efficiency and welding quality. The system can accommodate changes in the workpiece, such as irregularly shaped seams or slight misalignments. This flexibility makes the welding process smoother and more reliable, ensuring consistent and high-quality welds every time.
Another advantage of the seam tracking system is its ability to work with robots. By integrating laser seam tracking systems into robotic welding setups, manufacturers can significantly improve weld quality and productivity. Under the guidance of the seam tracking system, the robot can precisely track the seam and accurately position the laser beam, so as to achieve consistent high-quality welding. Additionally, the use of robots eliminates the need for manual labor and reduces the risk of human error, further increasing the overall efficiency of the welding process.
Improve weld quality and reduce rework time
One of the most desirable outcomes of any welding process is to achieve high-quality welds that do not require rework. Seam tracking systems play a vital role in this. By ensuring precise laser positioning, the system minimizes the risk of rework due to welding defects. Not only does this save time, it also reduces costs associated with rework, such as additional labor and materials. With the help of seam tracking systems, manufacturers can reduce weld defects, thereby improving overall weld quality.
Additionally, seam tracking systems help reduce the time required for rework. Since it produces precise and consistent welds, no adjustments or corrections are required after the initial weld is complete. This saves time and effort, allowing manufacturers to allocate resources more efficiently and meet tight production schedules. The seam tracking system simplifies the welding process, eliminates unnecessary delays, and increases productivity.
Increase productivity
Integrating a laser seam tracking system with a robotic welding setup can significantly increase productivity. The combination of robotic automation and precise laser positioning not only reduces the time required for rework, but increases the overall speed of the welding process. By eliminating manual labor, manufacturers can achieve faster, more efficient production lines.
In addition, a seam tracking system ensures consistent and high-quality welds throughout the production process. This eliminates the need for constant monitoring and adjustment, as the system continuously tracks and adjusts the laser beam in real-time. This allows operators to focus on other tasks, further increasing productivity. With laser welding machines equipped with seam tracking systems, manufacturers can optimize resources, increase production and meet customer demands more efficiently.
In conclusion, the seam tracking system of laser welding machine has many advantages, which can improve the production efficiency and welding quality. From precise laser positioning to improved production processes, the system ensures precise and consistent welds while reducing rework time and costs. When combined with robotic welding units, laser seam tracking systems can further improve efficiency, allowing manufacturers to increase production and meet customer demands more effectively. By investing in a laser welding machine with a seam tracking system, manufacturers can expect to improve weld quality, increase cost-efficiency, and improve overall productivity.
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