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2D/3D profile sensor for weld seam inspection

Weld 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 joint afterwards. For this purpose, welding systems are equipped with the innovative weCat3D 2D/3D profile sensors for weld seam inspection.

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

Animated analysis of the weld
During the visual weld seam inspection, the profile sensor is guided along the real welding seam. The sensor is positioned so that the profile line generated is perpendicular 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

Automated industrial welding
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
  • Laser welding (EN ISO 4063: Process 52)
    Laser welding permits high welding speeds with highly precise results 

Irregularities After Applying the Welding Seam

No seam

Welding seam: No seam


Welding seam: Hole

Missing edge formation

Welding seam: Missing edge formation


Welding seam: Pore


Welding seam: Protrusion


Welding seam: Curvature

Seam angle

Welding seam: Seam angle

Seam angle

Welding seam: Seam angle

Welding seam position

Welding seam: Welding seam position

Root sag

Welding seam: Root sag


Welding seam: Clearance

Root concavity

Welding seam: Root concavity


Welding seam: A-dimension

A-dimension camber

Welding seam: A-dimension camber


Welding seam: Dipping


Welding seam: Arching

Seam burr

Welding seam: Seam burr

Edge height

Welding seam: Edge height

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!


Find out more now!

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