High-Precision Laser Seam Tracking System: Intelligent Real-Time Joint Guidance for Automated Welding
As a leading technology partner, we develop high-precision sensor systems for real-time seam tracking and joint guidance in automated high-speed welding processes. Our systems instantly detect and correct component tolerances and positional misalignments on the fly. This ensures maximum path accuracy and defect-free series production for manufacturing companies worldwide.
Eliminating Beam Offset in Automated Production Lines
In modern, automated series production, even small tolerances in the workpiece or clamping can significantly reduce yield. . If the laser beam drifts away from the actual joint due to clamping variations or material warping, severe bonding defects may go unnoticed until costly post-process destructive testing reveals them. This creates a significant financial risk involving rejected component batches, expensive rework, or critical product failures in the field.
Our Solution: Our inline seam tracking system, OCT 250, makes hidden welding processes fully transparent by detecting deviations within milliseconds of their occurrence. Through seamless inline monitoring across all process phases, it actively counteracts path deviations and adjusts the position and welding parameters accordingly—before costly scrap is generated.
OCT 250: Seam guidance (Pre-Process), weld penetration depth measurement (In-Process), and seam inspection (Post-Process) — all combined in real-time process monitoring.
Welding Defects You Prevent with a Laser Seam Tracking System
Continuous path tracking protects your automated production line from hidden structural defects. Our non-contact sensor solutions intervene directly in the process to reliably prevent the following quality issues:
Incomplete Joint Fusion
Even minor beam offset or local contamination prevents the uniform melting of the two joint partners.
Insufficient Weld Depth
Missing the joint can alter the focal distance, reducing penetration depth and compromising both mechanical strength and electrical conductivity.
Thermal Overload
If the tracking system fails and the laser slips off the edge, excessive energy can burn through delicate underlying components or thin metal foils.
Gaps
In-process detection of gaps allows the welding parameters to be adapted to compensate for the gap and ensure a reliable weld.
Non-Contact Real-Time Path Correction
Automated seam tracking and joint guidance ensure that laser energy is delivered precisely to the correct geometric interface between the components. Our intelligent sensors scan the joint profile entirely without contact and with micrometer-level precision, directly ahead of the melt zone. If a misalignment is detected, the system automatically realigns the beam path or focal position through optical or mechanical adjustment within fractions of a millisecond. This keeps the weld seam perfectly centered, even during unpredictable thermal shifts.
Our Product Solutions for Laser Seam Tracking
OCT 250
Based on Optical Coherence Tomography, this cutting-edge system scans the joint profile contactlessly at 250,000 measurements per second, remaining completely unaffected by intense process glare or weld smoke. The sensor system is compatible with all common laser welding optics and, since this year, can also be used for GMAW (MIG/MAG) arc welding.
LSO (Lens Shifting Optics)
This adaptive processing head, including an OCT system automatically compensates for positional tolerances of up to 2.5 mm by dynamically adjusting the focal position via internal lens shifting every 10 ms.
OCTSCAN 2.5
This fully integrated scanner system solution guarantees seamless 3D path tracking and depth measurement along highly complex component contours during remote laser welding.
Why Global Manufacturers Rely on Our Joint Tracking Systems
- Closing the Technology Gap: The LSO system seamlessly bridges the functional gap between rigid fixed-focus heads and highly complex scanner-based welding optics.
- Compact Black-Box Integration: For system integrators, the combined LSO and OCT unit acts as an autonomous black box that can be easily integrated into existing robot cells.
- Maximum Dynamic Performance: Correcting the beam position directly inside the optical head eliminates unproductive positioning phases, maximizing your throughput.
- Industry-Standard Connectivity: All tracking and quality data are continuously archived and automatically transferred to your master machine controller via established industrial interfaces like EtherCAT or PROFINET.
OCT Presentation at the Leading International Trade Show „Laser World of Photonics“
Remote Laser Welding Optics OCTSCAN 2.5 with the OCT 250 Monitoring System
Secure Perfect Beam Alignment: Consult with Our Experts
Want to find out how a laser seam tracking system can eliminate beam offset and maximize your cycle times? Our application engineers will analyze your specific task and configure the ideal tracking solution for your laser welding line.
Richard Steinbrecht, CEO
Phone: +49 (0)89 – 360 90 48 – 102
sales[Ω]lessmueller.de