Illumination and Camera Modules for laser remote welding

The tried and trusted seam tracking system FILLET SCAN is an integrated modern beam guiding solution for robotic scanner welding, which allows:

  • Fast on-the-fly and position controlled omnidirectional welding with solid state laser
  • High accuracy real-time detection of the laser beam position and the location of the seam joint; fast on-line correction of the welding location
  • LIVE camera imaging and real-time image analysis to ensure optimum quality welds
  • Communication via standard Ethernet UDP fieldbus

First-time use of laser remote welding with FILLET SCAN for the production of doors
© BMW Group


The FILLET SCAN system ensures precise no-contact finding and tracking of the seam as well as real-time process visualization and process monitoring of laser remote welding. The seamless integration of the FILLET SCAN camera and illumination technology into Scanlab intelliWELD 30 FC V scanners yields premium quality welds.

WELDEYE camera module CM 3.0WELDEYE illumination moduleIntegrationVisualization and seam tracking with WELDEYE quality system

 

The combination of the dynamic WELDEYE camera CM 3.0 and a coaxial planar unstructured illumination with a high power 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 sequential high resolution images per second are acquired. Image data processing algorithms analyze every recorded image. The actual position of the processing beam and of the seam joint is determined in real-time.

Via the direct and fast communication interface the determined values are transferred to the Blackbird steering software to adjust the welding location. Additionally, the interface is used for the exchange of general control and quality signals.

A live video-observation of the welding process provides evidence regarding process quality.

Quality control algorithms, which are approved during the serial process, monitor the position control as well as the welding process, and report critical components to the superordinate system control.

Advantages:

  • Precise closed loop controlled seam tracking and visualization of the welding process to achieve premium quality welds regardless of process emission
  • Online automatic determination of the beam position and the actual seam joint location
  • Online seam tracking (for fillet welds) in the entire scan field and in any direction
  • High speed acquisition, evaluation, video recording and documentation (including quality assurance) as well as review of the recorded data for post-analysis