Illumination and Camera Modules for laser welding

The WELDEYE smart quality system has been further developed for the HIGHYAG PDT-B laser head supplying it with automated monitoring and quality control functions for premium weld / braze quality:

  • Real-time process visualization, monitoring and quality assurance for tactile guided laser welding and brazing
  • Synchronous recording, evaluation and documentation of video based data and process parameters (wire speed etc.)
  • Online detection and auto-correction of weld faults before the weld fails, reducing scrap rate, test costs and rework
  • Communication via standard fieldbuses (Profinet, Profibus, Ethercat, Devicenet, Ethernet/IP)

WELDEYE for HIGHYAG PDT-BIntegrationVisualization, process monitoring and quality control with WELDEYE quality system

The seamless and maintenance-free integration of WELDEYE camera and illumination technology into HIGHYAG PDT-B laser heads complements the HIGHYAG PDT-B with a smart no-contact real-time inspection system.

The coaxial combination of the dynamic WELDEYE camera and a powerful planar unstructured illumination by a narrowband light source is a key technology for the visualization of the welding process area and its surrounding along the entire scanning range.

During the active welding process, the process light is optimally suppressed by a narrowband filter. 300 images per second are alternately recorded with and without external illumination.

In no-illuminated images the intensity of the reflected process light is examined. Illuminated images reproduce with high resolution the regions around the process beam, in particular the cooled seam surface together with the distribution profile of the light reflected off the seam. The actual seam profile is generated from image to image and compared with the reference.

The image processing signals serve for quality control purposes and an automated online determination of weld faults.

Advantages:

  • Combined camera/illumination unit: omitted opening of the beam pass, unchanged obstacle contour
  • Crosschecking of the beam-wire position with OPTIKCHECK in the production line
  • Measurement of the weld gap width directly before the welding process
  • Robust industrial construction with robot-drag adapted cables and interfaces
  • Compact, maintenance-free and lightweight system and cost-effective design