The use of automated monitoring systems in laser welding leads to a transparent and stable process. Process changes are detected at an early stage and relevant parameters are corrected if necessary before poor welding results occur. Real-time process monitoring makes a decisive contribution to reduce downtimes and scrap production, inspection costs and rework rates.

Lessmüller Lasertechnik offers users smart tools for various laser welding optics that enable them to track, understand and optimize processes for seam tracking:

• The OCT (optical coherence tomography) system offers highly accurate, non-contact surface measurement of all common joining points as well as dynamic position correction of the processing laser beam during the welding process in real time. Hairpins can also be precisely measured with this system in terms of their geometry and position relative to one another in order to achieve an optimum welding position. In principle, OCT is compatible with all common welding optics.

OCT visualization of a weld topography

• The WELDCHECK system (photodiode-based) is ideal in process monitoring, when welding fine spots and seams (seam tracking). It monitors the intensity of the process light and detects deviations from the target value. The effective as well as cost-efficient system is especially used to determine production rejects according to individually definable parameters.

Screenshot shows error detection with WELDCHECK

• The WELDEYE system is used for synchronous recording and evaluation of image data and process parameters by means of camera- and extraneous light-based real-time process visualization.

WELDEYE live recording of a melting bath

All measurement and evaluation data of these systems can be stored in each case and thus enable complete traceability.

At home in many industries