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
How the Weld Seam Inspection Works
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
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
Hole
Missing edge formation
Pore
Protrusion
Curvature
Seam angle
Seam angle
Welding seam position
Root sag
Clearance
Root concavity
A-dimension
A-dimension camber
Dipping
Arching
Seam burr
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:
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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!
