Arc-Eye CSS laser visionsystem
3D laser vision
Welding seam tracking with
Valk Welding email@example.com www.valkwelding.com
Makes it happen
Seam tracking for weldin
Valk Welding develops and builds the Arc-Eye CSS (Circular Scanning System) laser sensor for real-time seam tracking applications. The Arc-Eye laser sensor system enables the welding robot to accurately track the joint to be welded during the welding process. This is achieved by scanning position, orientation and geometry of the part and automatically correcting the movements of the welding robot where necessary. The Arc-Eye laser sensor registers all measurement deviations within the scanning range of the laser sensor. This does away with the need to measure deviations beforehand and correct them manually in the welding program. This substantially increases the return and quality of the robotised welding process.
Benefits of seam tracking with a laser visionsystem • delivers a precisely welded seam • manual program corrections no longer required • complex welding jigs no longer required • raises the process speed • raises the process precision • prevents unnecessary rejection
Deviating measurements compared to programs?
Products that are a precise fit for the welding robot can theoretically be welded one by one by the robot without any program corrections. However in practice the welding seams may deviate from the program positions owing to the material being warped by the one-sided application of heat. With steel structures in particular, deviations over large lengths can sometimes run up to several centimetres. Irregular weld-gaps and complex shapes often need to be corrected in a robotised welding process.
How can this be prevented? Various methods have been developed to ensure that the welding robot precisely moves along the joint to be welded. Pre-weld touch sensing by using the gas cup of the welding torch, is the best known example. The use of this method is however restricted to corner-joints and T-joints. Touch sensing with the aid of the welding wire, which Valk Welding has developed into the Quick Touch System, does not have that restriction and is therefore gaining in popularity. Both methods check the welding seam before the start of the welding process.
Why a vision system?
The advantage of using a laser vision system, which scans the seam to be welded during the process, is the ability to track and thus follow any deviation in realtime. Deviations are immediately detected and adapted during the process so that the welding robot precisely moves along the actual position of the seam to be welded. While using a laser sensor there is no need to check the route positions first by using the gas cup or welding wire. This way cycle times are substantially reduced.
Arc-Eye 3D laser visionsystem
ng with Arc Eye
Integrated in Valk Welding tool change The Arc-Eye laser sensor is fully integrated in the Valk Welding tool change system. This guarantees perfect calibration of the laser sensor in relation to the Tool Center Point (TCP). Valk Welding’s software engineers have made a special software interface with the Panasonic welding robots for this purpose. Valk Welding thus offers a seam tracking system for welding applications based on laser vision that is completely integrated into one single system.
Benefits of the Valk Welding Arc-Eye vision system
• fully integrated in Valk Welding torch switching • perfect calibration of the camera system in relation to the TCP • resistant to heat and dirt during the welding process • usable as plug and play system on any Panasonic welding robot • position, orientation and welding seam geometrics measurement possible in just a single scan
Valk Welding offers welding seam tracking with the Arc-Eye laser sensor in its welding robot systems and other mechanised systems. As well as time savings, the Arc-Eye laser sensor systems make a substantial contribution to raising product quality, consistent replication, effective deposition of welding additives and improved heat distribution. The latter point results in less product deformation and a neater welding seam.
The Arc-Eye laser sensor is suitable for detecting and automatically tracking virtually all welding seams that are found in practice. The Arc-Eye laser sensor corrects the set welding parameters and robot movements in realtime during the production process. The Arc-Eye laser sensor makes it possible to use the robot to weld work pieces with an irregular weld-gap of the welding seam, non-constant measurement tolerances and complex shapes without any manual corrections or search routines being needed in advance. This creates options for the robotised or mechanised welding of complex work pieces in single or small series.
Specifications of the Arc-Eye laser sensor The Netherlands Valk Welding B.V. Staalindustrieweg 15 Postbus 60 2950 AB Alblasserdam firstname.lastname@example.org www.valkwelding.com Tel. +31 (0)78 69 170 11 Fax +31 (0)78 69 195 15 Belgium: Valk Welding NV Tel. +32 (0)3 685 14 77 Fax +32 (0)3 685 12 33 France: Valk Welding France Tel. +33 (0)3 20 10 00 39 Fax +33 (0)3 20 10 01 12 Denmark: Valk Welding DK S/A Tel. +45 44 68 31 81 Fax +45 44 68 31 87 Czech Republic: Valk Welding CZ s.r.o. Tel.: +420 556 730 954 Fax: +420 556 731 680
Steenkist Communicatie - ww.steencom.nl - 2013
sensor diameter : 45 mm sensor length : 135 mm weight : 500 grams operational temp* : +5ºC - +40ºC ambient temp* : -10ºC - +60ºC cooling : with dry, clean air from +10ºC - +30ºC welding seam forms : commonest types max speed : depending on the welding process scanning speed 4000 measures a second detection : linear CCD Stand-off type : short / medium / Long resolution depth : 25µm / 60µm / 125µm sideward resolution : 45µm / 80µm / 175µm visible field : 12mm-18mm / 20mm-34mm / 38mm-76mm visible depth : 30mm-50mm / 50mm-100mm / 75mm-165mm nominal distance : 40mm / 75mm / 120mm laser output : 670 nm, 4.5 mW, class 3R system output : digital/analogue i/o, rs-232, Ethernet * Arc Eye is equipped with a sensor which automatically shuts down the system when the inside temperature is above 60 ºC.