LWM (LASER WELDING MONITORING)
The Laser Welding Monitor LWM 4.0 is used for the online process monitoring in many areas of industrial production in 24/7 operation. In series production, it detects and documents a wealth of quality and productivity relevant information to the laser welding seam. Thus, quality fluctuations caused by component tolerances, contamination, or different material batches can be monitored and detected.
The system is easy and intuitive to use and provides you with helpful data on your laser welding seam. The allocation to each component is done via communication with the system control/SPS. All data is stored and documented continuously, even during ongoing production. In combination with online backups, the LWM 4.0 thus enables 100 % traceability and transparency of your laser welding processes – even after many years.
The reliable complete solution detects changes in welding parameters, deviations in the weld seam, and binding defects. Component deviations such as burr at the weld joint or faulty clamping devices are detected, as well as deviations in the welding depth. The fingerprint of the welding process is determined, compared with the signals of your current production, and transmitted in real time. Thus, welds can be specifically classified and rejected in case of abnormalities. This is a significant contribution to the reduction of rework.
The introduction of new material batches into production can lead to systematic, erratic shifts in process signals. These values can be detected by the intelligent software package and the good part classification can be automatically adjusted. Due to this automatic adaptation, good parts are still classified as good parts and therefore no need for a new teach-in.
During the mass production process, wear and tear of individual machining tools occurs. This can influence the joining process and thus the quality of the laser weld seam. The LWM 4.0 process monitoring system detects this systematic, continuous shift in signals and provides the user with early feedback via adjustable warning levels. Furthermore, these trends can be evaluated via individual statistics.
IDM (IN DEPTH MONITORING)
The Precitec IDM measures welding depth coaxially during the laser welding process. Measurement data is always recorded directly from the lowest point of the keyhole based on OCT technology – even at very high welding speeds. The Precitec IDM offers you continuous quality monitoring during the entire laser welding process. Costly and time consuming cross section analyses or destructive tests can be reduced to a minimum.
The measuring data recorded during the welding process are used for 100% quality control. By setting upper and lower limits, an immediate warning can be sent to the system control or the machine operator if the values are exceeded. Production errors are detected immediately and can be corrected in time. The data storage in combination with the component ID enables consistent traceability – even years later. This means that the collection, evaluation, and documentation of the data including proof of quality is at your disposal – a comprehensive determination.
In addition to the pure measurement, the Precitec IDM offers the possibility to automatically control welding depth. For this purpose, permanently determined actual values are compared with the target values and the welding depth is controlled in real time by adjusting the laser power. In this way, a reliable and reproducible welded joint can be guaranteed, even with demanding and safety-relevant components. The package is rounded off with a user-friendly and intuitive software solution.
By the absolute measurement of welding depth, scrap can be specifically identified and an automated ejection can take place. This also has the advantage that rework costs are reduced to a minimum.
WELD MASTER (The automated total solution for your laser welding)
A highly accurate tracking of the joining position, intelligent beam guidance and forming as well as online quality control – the WeldMaster 4.0 offers you all this for your automated welding process. This allows you to implement a complete solution in just one welding station, which is designed for the modern requirements of everyday industrial use.
The WeldMaster tracking system measures essential geometric variables in the immediate vicinity of the welding position, from which the component position, joining position, and gap are calculated. The information is processed by the system contro,l and controls beam guidance and forming by means of linear axis and galvanometer scanner. Even for components with tolerances, you get stable welding processes and consistent quality at all times, and independent of material and seam geometry.
In the immediate aftermath of the laser welding process, the geometric quality control of the joining seam is performed in real time. The Inspect system of the WeldMaster 4.0 eliminates the need for an additional quality station in the flow production. You can measure and evaluate many types of defects such as pores, holes, gaps, notches, and weld formations such as convection, seam width, or the general seam geometry for a wide range of seam shapes.
The data from tracking, process control, and inspection are permanently stored and are available to the user. Even after years, the results of the laser welding process can be queried and traced. By assigning customer and component numbers, 100% traceability is possible. An extraordinary feature of the WeldMaster 4.0 is the combination of several systems to a WeldMaster 4.0 network.