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Robust Profile Sensor
weCat3D MLZL

The MLZL 2D/3D profile sensors from the weCat3D series are designed for fully automated weld seam tracking, where the highest demands are placed on quality and precision. The sensor reliably detects the position of the joint to be welded via laser triangulation.

Technical Data for Explorers

The MLZL design, specially designed for use in welding processes, is particularly compact in order to prevent the occurrence of interference contours on the welding torch. Even on difficult surfaces, the profile sensor optimized for weld seam tracking offers good profile quality without noise. The integrated cooling and air flushing enables use in hot and dirty industrial areas, while the adjustable cover protects the welding optics from the brightness and heat of the arc.

Discover more technical features of the MLZL tracker sensor in our interactive overview.

The Technical Highlights in Detail

Optics

High-quality optics with replaceable protective screen
- High-performance camera with a resolution of up to 32 μm in X or 8.3 μm in Z and a measuring rate of up to 4,000 Hertz
- Simple protective screen replacement without tools: Slide on protective screen retainer, replace screen, reinsert protective screen retainer
- Protective screens available in glass and plastic
Guard Plate

Continuously adjustable guard plate
- Flexibly adjustable metal guard plate to protect the optics from the brightness and heat of the arc for high profile quality
- Mechanically and continuously adjustable via a fixing screw (Torx TX8)
Air Flushing

Air flushing for interference-free visual field
- Integrated air flushing to prevent contamination of the optical windows in front of the laser and camera, which could impair the function of the sensor
- Special color-coded push-in connector (blue) for quick and secure connection to the air supply without tools
Cooling

Integrated cooling
- Integrated cooling option to prevent overheating of camera and laser due to the high ambient temperature in welding applications
- Optional cooling with air or water for higher cooling capacity
- Special push-in connection for quick and secure connection to the media supply without tools
Filter

Optical filter for interference-free point cloud
- High-quality, narrow-band interference filter with high resistance to ambient light
- Effective suppression of interfering light outside the laser wavelength for a clear image without major artifacts due to the welding process

weCat3D MLZL at a Glance

Visual Field MLZL

The Visual Field

Challenge with Weld Seam Tracking: Joint Types

With optical weld seam tracking, the position of the objects to be welded together must be reliably detected in order to ensure precise application of a high-quality weld seam. A distinction is made between different types of joints.

Butt joints

Lap joints

Parallel joints

T-joints

Double-tee joints

Corner joints

Multiple joints

Angular joints

The MLZL weCat3D profile sensor uses the weld tracking module of the uniVision software, which enables reliable detection of the guide point thanks to a special algorithm for all types of joint and thus guides the welding unit precisely.
Watch the MLZL tracker sensor in action during robotic welding in the following video. The joint types T-joint, butt joint and lap joint are shown.

Integration Options in the Welding Process

There are various options for integrating the MLZL 2D/3D profile sensor in weld seam tracking. With its special housing shape, the robust sensor is particularly suitable for use in robotic welding, but can also be used in welding applications with third-party software.

Robot Weld Seam Tracking

Weld Seam Tracking with Control Unit and Robot

With sensor-guided weld seam tracking in robot cells, the MLZL weCat3D sensor detects the joint before the automated welding process and passes on the exact positioning to the robot, which then corrects its path and applies the weld seams precisely.
The robot moves through three dimensions including rotations, which requires more complex calibration and robot path programming.

When solving high-frequency welding applications with the MLZL profile sensor, the control unit BB1C009 with uniVision software and matching robot plugins enables quick and easy integration and setup. The sensor and control unit as well as the robot control and robot communicate via the Ethernet TCP/IP industrial interface.

The compact and slim design of the MLZL sensor for weld seam tracking prevents the occurrence of an interfering contour on the welding torch and thus enables robot welding in gaps and corners.

uniVision Templates for Optical Weld Seam Tracking

uniVision software contains a special module for weld seam tracking, which ensures reliable and stable detection of all types of joints before the welding process.
Templates tailored to the application of weld seam tracking offer pre-parameterized templates for the most common joint types for quick and easy setup of weld seam tracking in the software.

Plugins for Robot Interfaces


FANUC interface plugin DNNP007	Yaskawa interface plugin DNNP008	KUKA interface plugin DNNP009	ABB interface plugin DNNP010	Kawasaki interface plugin COMING SOON!

FANUC interface plugin

DNNP007

Yaskawa interface plugin

DNNP008

KUKA interface plugin

DNNP009

ABB interface plugin

DNNP010

Kawasaki interface plugin

COMING SOON!

Robot Weld Seam Tracking with MLZL

Weld Seam Tracking in Robot Cells by MLZL 2D/3D Profile Sensor

In fully automatic robot welding cells, it is necessary to determine the exact positioning of the joints on edges, angles or steps before the welding process. For this purpose, a 2D/3D profile sensor is mounted directly next to the welding torch on the robot. Thanks to a protective housing, the sensor is protected against welding spatter. The sensor measures the interface via laser triangulation. The results are processed via uniVision software and sent to the control unit. The welding robot thus moves along the contour and connects the objects with a welding seam in the same movement sequence.

Weld Seam Tracking with Third-Party Software

With sensor-guided weld seam tracking, the MLZL weCat3D profile sensor detects the joint before the welding process and transmits the exact positioning to the higher-level control system, which then corrects the path and ensures precise application of the weld seams.

The MLZL profile sensor for weld seam tracking is integrated into new or existing systems with third-party software via the industrial interfaces TCP/IP or GigE Vision. SDKs are offered free of charge for this purpose.

Product Comparison

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Robust Profile SensorweCat3D MLZL