Pros And Cons of All The Different Seam Tracking Solutions (2)

4. Tactile seam tracking

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Tactile is a physical contact probe that touches the material. Haptics are often used in hard automation and some laser brazing applications, rather than seam tracking applications for 6-axis robots. It installs a tip or probe inside the welding joint, and detects the deviation of the edge in contact with the original source, and adjusts its cross slider accordingly to position it correctly on the weld.

Tactile seam tracking has a very simple operation function and can be applied to various processes, including sub-arc, arc-opening and brazing, which makes it a very versatile form of seam tracking. The sense of touch is also not limited by any material, so you can touch the seams, from stainless steel to aluminum, without any impact on the system.

Maintenance is an important part of keeping the tactile tracking system working properly. Because the tip is in constant contact with the engagement surface, component wear often occurs in the haptic system. When its tip wears out and becomes shorter, it will bring your welding tool forward and close to the joint, which can cause poor welding or completely damage the front end of the torch. It is very important to check whether the probe is worn or not to ensure that the probe is properly separated from the torch to obtain high-quality welding.

Haptic solutions should be checked and maintained more frequently than non-contact solutions for other items such as welding spatter and cable management conditions.

Tactile seam tracking solutions are also not suitable for nail welding. As is generally recommended, the nail can lift the probe over the tack welding and direct the arc in the same direction, instead of letting the torch weld through the tack.

Tactile seam tracking is also not suitable for adaptive. These types of systems follow the joint line and do not consider mismatches or gap sizes due to tools. Area calculation is also impossible. A tactile probe will lock in a groove and follow it with minimal deviation. A sufficiently large change in the groove or a large enough spot weld can cause the probe to escape its desired track.

For welding profiles like butt welds, it is difficult to track tactile welds without gaps. Non-linear welding forces the probe to move sharply in one direction, which is not ideal for tactile seam tracking applications; it is suitable for large cylindrical welding or pipe welding.

Travel speed is another limitation of tactile seam tracking because it usually moves at a lower speed, which slows down your cycle time.

Comparing tactile and vision-based seam tracking is a contact-based approach and another non-contact problem. Although haptic seam tracking is a mechanical setting, it is usually a lower upfront capital investment. The haptic tracking system in open and secondary arc applications requires more maintenance because it is a mechanical process that has a long-term Can make it a less cost-effective solution. The sensitivity of the measuring body and the continuous wear and tear of the components.

5. 3D laser weld tracking

The 3D laser seam tracking system is also called optical or visual seam tracking and uses the principle of laser triangulation. The laser seam tracking system can be used on hardware automation and robotic systems, and the correct software package can be used.

Conceptually, laser seam tracking involves a laser beam emitted from the device, hitting the surface, reflecting off the surface, bounced back to the sensor, and the sensor picks up the location where the beam hits. Therefore, through laser seam tracking, the sensor can know the distance between the laser transmitter and the sensor on the camera, so that it can triangulate the material that it bounces back.

Essentially, you can get the Z (height) and Y (lateral) images of the joint, so the sensor knows the image it bounces from the X (distance) size of the light away from the sensor, and its features in the Y-direction field of view Choose whether it is positive or negative.

Laser weld tracking does not know the X direction or the length of the part. This is why you use the equipment in conjunction with a control system, which defines the X value-a process called calibration. After calibration, the seam tracking system will identify the X, Y and Z positions throughout the welding process.

Any seam tracking solution for the welding process will increase the cycle time, but laser seam tracking increases the cycle time the least-usually the welding cycle per scan is about a quarter of a second. It can also move the fastest. Optical tracking can reach 200 inches per minute, so if high travel speeds are required, it will not limit the robot or gantry speed. Laser welding seam tracking can also be used in processes other than welding, such as gluing, spraying, and polishing.

Laser has a unique advantage over TAST because it allows the device to run dry on the part or view it offline. Since the tracking is only based on the imaging of the part, inconsistencies in materials such as rust, scales or even tack have little effect on laser weld tracking.

The gap for laser weld tracking is a limitation. The direction of travel is another consideration because the sensor must always guide the welding path. This can lead to robot arrival problems, torch angle problems, and careful consideration of the tooling and design of the components.

Generally, the only difficult to apply laser weld tracking is shiny materials. The reason is that whenever laser light is emitted from a material, it must be reflected. Consider the different weld joint types and how they reflect the laser beam depending on the material. In the knee joint, it reflects directly back. If it is a V-joint, it will not only reflect the straight back, but also reflect the opposite angle it reflects-almost like a disco ball. In these cases, it is difficult for the sensor to determine which beam is reflected back to be the correct beam. You have a lot of fake beams coming back, it looks like a crosshair because you get a lot of reflections.

Laser welding seam tracking cannot fully track material-joint combinations such as fillet welds of aluminum alloy diamond plates. Other combinations, such as stainless steel inner corners with mirror finish, are also very difficult surfaces and joints for seaming tracks. Although optical systems can be used to track these combinations, special familiarity with laser slit tracking sensors is required to repeat this.

Precise positioning depends on laser

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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. 

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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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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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What is Welding Seam Tracking?

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.

Different Types of Welding Seam Tracking Solutions

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:

• Touch Sensing
• Through Arc Seam Tracking
• Tactile Seam Tracking
• 2D Vision Systems
• 3D Laser Seam Tracking

Weld Seam Tracking is a Complex Process!

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:

• Extensive programming of the system that will require skilled employees
• Increased lead times when taking on new jobs to ensure the automation works according to the specification
• Welding programmers who aren’t easy to find, meaning the job will often cost more, especially in high-mix, low volume runs.

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. 

What is a Welding Cobot?

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.

How Welding Cobots Do Not Need Seam Tracking

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:

• The complexity and need for high programming skilled workers defeat the goal of a welding cobot in the first place, which is to leverage the welders you already have to teach the new robot.
  
  
• The time to implement and program these technologies is long and costly. They keep the manufacturer from starting the production sooner and get faster ROI. Moreover, automated sensing and weld seam tracking systems increase cycle times by three to five seconds for each sensing operation.
  
  
• Simplifying the welding cell with repeatable jigs removes the need for advanced technologies. With precise fixture designs and experienced welding staff, you can maximize your throughput and reduce cycle times for each welding workflow. 
  
  
• Moreover, some welding cobots come with cloud-connected notifications if the robot encounters an issue. This will help you monitor if the repeatability of your parts is a cause.
  
  
• Lastly, suppose your parts have so much variability that the robot cannot follow the joints. In that case, you should evaluate your upstream production to fix the issue at the source instead of welding potentially scrap parts.

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.

Why Welding Cobots Perform Better Without Welding Seam Tracking Systems

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. 

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