Weld Seam 3D Scanning for In-Process Laser Welding Quality
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Solution Overview
Problem
Existing methods for testing laser beam welding outcomes are time-consuming and often destructive, limiting their applicability to random testing and preventing real-time monitoring of geometrical variables and quality features of weld seams.
Innovation Solution
A method and device that scan the weld seam using a measurement beam during the welding process to acquire data points, allowing for the simultaneous determination of geometrical outcome variables and quality features, enabling online monitoring and adjustment of the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If destructive tests (micrography) are used to test weld seam outcome, then measurement precision is improved, but productivity deteriorates due to time-consuming processes and destruction of the weld seam
Solution Approach 1:
The patent replaces mechanical destructive testing (micrography) with optical measurement systems (laser triangulation, camera-based systems) that can measure weld seam geometrical variables non-destructively in real-time, eliminating the need to destroy the weld seam for testing while maintaining measurement precision
Solution Approach 2:
The patent creates optical copies (images, point clouds, 3D models) of the weld seam geometry through non-contact optical scanning, allowing virtual measurement and analysis without physical destruction of the actual weld seam, thus enabling both precise measurement and continuous production
2Productivity
If visual inspection by camera is used, then productivity is improved through nondestructive testing, but measurement precision deteriorates as not all geometrical outcome variables can be tested
Solution Approach 1:
The patent transitions from 2D camera imaging to 3D optical measurement systems (laser triangulation, structured light scanning) that capture depth information and geometrical variables in three dimensions, enabling precise measurement of weld depth, penetration, and complex geometrical features that 2D cameras cannot detect
3Measurement precision
If downstream testing is performed, then measurement precision is improved for weld seam quality assessment, but loss of time increases making it suitable only for random testing
Solution Approach 1:
The patent performs weld seam measurement and quality assessment during or immediately after the welding process itself (in-line or on-line measurement), rather than after the welding is complete (downstream testing), enabling real-time quality control and eliminating the time delay between welding and testing
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces testing time, allows for accurate and nondestructive evaluation of weld seams, and enables real-time adjustments during the welding process, improving the efficiency and quality of the laser beam welding process.
Implementation Method 1
scanning the weld seam using a measurement beam during laser beam welding of the weld seam in order to acquire data points
Data Source
AI summary
A method for determining at least one geometrical outcome variable and/or at least one quality feature of a weld seam on at least one workpiece includes scanning the weld seam using a measurement beam during laser beam welding of the weld seam in order to acquire data points. The measurement beam is moved along at least one measurement path on the weld seam. The acquired data points indicate a height and/or a depth of the weld seam in relation to a workpiece surface of the at least one workpiece. The method further includes determining the at least one geometrical outcome variable and/or the at least one quality feature by evaluating the acquired data points.