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Welding Seam InspectionWith 2D/3D Profile Sensors

Welding Seam Inspection
With 2D/3D Profile Sensors

During welding, the type of material, the welding technique used and the ambient conditions determine the result. It is therefore important to check the welded connections afterwards. For this purpose, welding systems are equipped with the innovative weCat3D 2D/3D profile sensors for checking welding seams.

Outstanding Performance and Efficiency: The weCat3D Series for Welding Systems

After the welding process has been completed, the result must be checked. Irregularities such as missing, double, undulated or other faulty welds are reliably detected by 2D/3D profile sensors and output via the defined interface. A common automatic test method is visual inspection. The use of a profile sensor offers decisive advantages in this procedure: the time required for checking and analyzing the welding seams is reduced without compromising on the quality of the inspection.
  • Precise checking along the welding seam
  • Excellent profile quality – even on reflective surfaces
  • Compact housing (IP67)
  • Easy sensor integration thanks to existing SDKs and the standard Ethernet TCP/IP interface
  • High profile density for the smallest error detection with Z resolution from 2 μm 
  • Material and color independent 
  • High measurement frequency



​​​​​​​Find out more in our application world.

How the Weld Seam Inspection Works

Animierte Analyse der Schweißnaht
During the visual welding seam inspection, the profile sensor is guided along the real welding seam. The sensor is positioned so that the profile line generated is orthogonal to the welding seam. The joining of the individual profiles in the application software creates a 3D image, which is examined by the software for irregularities – taking into account a set tolerance. If deviations are found during the subsequent evaluation, a corresponding signal is output by the software.

Versatile for Welding Processes

Automatisiertes Industrie-Schweißen
With the following types of welding, for example:
​​​​​​​
  • MIG – Metal Inert Gas
    Metal welding with inert, i.e. inactive gases
     
  • MAG – Metal Active Gas
    Metal welding with active gases
     
  • ​​​​​​WIG – Wolfram Inert Gas
    ​​​​​​​Metal welding with a non-melting pure or alloy tungsten electrode

Irregularities After Applying the Welding Seam

No seam

Schweißnaht: Keine Naht

Hole

Schweißnaht: Keine Naht

Missing edge formation

Schweißnaht: Keine Naht

Pore

Schweißnaht: Keine Naht

Protrusion

Schweißnaht: Keine Naht

Curvature

Schweißnaht: Keine Naht

Seam angle

Schweißnaht: Keine Naht

Seam angle

Schweißnaht: Keine Naht

Welding seam position

Schweißnaht: Keine Naht

Root sag

Schweißnaht: Keine Naht

Clearance

Schweißnaht: Keine Naht

Root concavity

Schweißnaht: Keine Naht

A-dimension

Schweißnaht: Keine Naht

A-dimension camber

Schweißnaht: Keine Naht

Dipping

Schweißnaht: Keine Naht

Arching

Schweißnaht: Keine Naht

Seam burr

Schweißnaht: Keine Naht

Edge height

Schweißnaht: Keine Naht

Practical Examples and Collaborations

The versatility of wenglor’s innovative sensor is underlined by its use in various industries. In combination with the robot cell and the integrator’s software, the desired welding result is ensured, which minimizes follow-up costs and maximizes product safety, for example. This is why they are used in numerous industries:
  • Automotive industry
  • Rail industry
  • Aviation industry
  • Heavy machinery manufacturing
  • ​​​​​Special machinery manufacturing
  • Steel industry

Discover the Versatility of 2D/3D Profile Sensors in Collaborations With Our Customers:

The Logical Step

With its TIVIS® software, our partner EHR provides a tool with which the welds recorded by the weCat3D 2D/3D profile sensor can be evaluated based on various parameters: Length, width, angle, cracks, edges or the curvature of common welding seams can be reliably detected, for example.

Maximum Precision for the Automotive Industry

With the support of our 2D/3D profile sensors, the Canadian robotics company Bluewrist has developed a system for the inline inspection of welding seams from robots, sensors, software and controllers. The complete system is fully automated to meet the requirements of the automotive industry – for example, when checking car components such as doors, tailgates or structural components – in terms of quality and precision. Watch the video to see how, among other things, we can successfully master the special case of checking a circumferential weld and measure complex surfaces using laser triangulation – with micrometer accuracy!

weCat3D

Find out more now!

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