Laser seam tracking is typically integrated into production lines and manufacturing processes that rely on automated welding, which is mostly done by welding robots. This includes the automotive and aerospace industries, as well as the manufacturing of construction equipment and heavy machinery, the shipbuilding industry, and metal fabrication.
A laser seam tracking sensor is used to significantly enhance the precision process by following the weld seam and guiding the automated welder. This has a positive effect on productivity, as it allows for a faster production project.
Namely, by accurately tracking the weld seam, the laser tracker reduces the need for manual adjustments, which leads to better positioning, faster welding, and, subsequently, a significantly increased throughput. At the same time, the likelihood of defects such as missed seams or inconsistent weld penetration is greatly reduced.
Furthermore, more advanced laser seam tracking systems are quite adaptable to variations in the weld seam and can accommodate any changes in alignment or seam geometry in real time. These factors contribute to a significant reduction in costs that are otherwise associated with re-work.
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Since welding technologies and welding techniques differ across different materials and applications, it’s only reasonable to conclude that laser seam tracking sensors differ as well.
Not all laser seam tracking systems are the same. Some rely on laser displacement sensors to perform 1D measurements, while others rely on laser profilers to perform 2D scans. In either case, both systems measure the distance between the sensor and the target surface, with the aim of identifying and tracking weld seams. In most cases, they do this by measuring height, where they either take a series of 1D measurements or 2D scans that detect height variations.
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Selecting the right laser weld seam tracking solution involves considering the specific requirements of your welding process, its environmental conditions, the materials and types of workpieces the process revolves around, and the level of accuracy and precision required by your application.
KEYENCE offers a comprehensive range of 2D/3D Laser Profilers that are great for all sorts of welding applications. So, if you’re interested in upgrading your current welding process by integrating laser seam tracking, don’t hesitate to contact KEYENCE and inquire about integration options with your current welding setup.
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