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Weldeye for ALO3

Weldeye for ALO3

With over 400 Lessmüller Lasertechnik systems installed worldwide, external illumination based WELDEYE offers trend-setting solutions for seam-tracking and quality assurance. The smart WELDEYE quality system has been customized to complement Scansonic ALO3, supplying it with visualization and automated quality control functions for premium weld / braze quality.

Function description

The integration of WELDEYE camera and illumination technology into the Scansonic ALO3 laser head (for magnifications 1.0, 1.1, 2.1., 3.3., 4.0, 5.2., 5.3.; for further magnifications on demand) creates the conditions for using all functions of the Lessmüller quality system. The combination of the dynamic WELDEYE camera AP 3.0 and the fourth generation illumination module with planar structured narrowband light source is a key technology for the visualization of the welding process area and its surrounding along the entire scanning range.

During the active welding process, the process light is optimally suppressed by a narrowband filter. 300 images per second are alternately recorded with and without external illumination. In no-illuminated images the intensity of the reflected process light is examined. Illuminated images reproduce the regions around the process beam with high resolution, in particular the cooled seam surface together with the distribution profile of the light reflected off the seam. The actual seam profile is generated from image to image and compared with the reference. The image processing signals serve for quality control purposes and automated online determination of weld faults.

Advantages

  • Development of precisely tailored algorithms, e.g. for the measurement of the weld gap width before the welding process or for crosschecking of the beam-wire position
  • Online detection and auto-correction of weld faults before the weld fails for reduced scrap rate, test costs and rework
  • High industrial suitability due to replaceable protection glasses and cross jet, integrated directly into the illumination module
  • Compact, robust, lightweight and cost-effectively designed system

Properties

  • Real-time process visualization, monitoring and quality assurance for tactile guided laser welding and brazing
  • Crosschecking of the beam-wire position with Lessmüllers OPTIKCHECK in the line production
  • Synchronous recording, evaluation and documentation of image based data and process parameters (wire speed etc.)
  • Customized programming of quality algorithms; personal support from our flexible in-house software department
  • Communication via standard fieldbuses (Profinet, Profibus, Ethercat, Devicenet, Ethernet/IP)
Wavelength of illumination laser 808 nm
Image rate (400 px x 400 px) 300 fps
Camera resolution 40 px/mm
Image pixel size 600 px x 200 px
Max. image size 16 mm to 18 mm x 6 mm
Pre-process area size in the welding direction 5 mm
Post-process area size in the welding direction 11 mm to 13 mm
Magnification, supported by Scansonic ALO3 1:1 / 1:1,1 / 1:2,1 / 1:3,3 / 1:4 / 1:5,2 / 1:5,3
Other Sequential switching from image size, image position, exposure and illumination time from image to image
Optical interface Motor-driven narrowband filter
Internal data interface (incl. 8 m and 15 m cable) Gigabit Ethernet
Interne Datenschnittstelle (incl. 8 m- und 15 m-Kabel) Gigabit Ethernet
Internal sensor/actor interface (with camera) CAN-BUS
External interfaces Profinet, Profibus, Ethercat, Devicenet, Ethernet/IP
WELDEYE AP 3.0 camera module size 82 mm x 82 mm x 86 mm
WELDEYE LM4 illumination module size 82 mm x 82 mm x 60 mm
Weight ca. 1200 g
External power supply 230 V
Internal power supply 24 V / max. 3 A
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