ANALYSIS: WELD MONITORING
produced a multi-factor report on the weld quality which then automatically combines the relevant data to make a pass/fail decision. Te machine controller is then signalled as to whether to scrap the part or not. In addition to reducing the need for several
different previous-generation monitoring technologies cluttering the laser head and working area, this weld monitoring technology has real potential to lower operating costs through reduced destructive testing.
Smart monitoring for sophisticated welds Inline weld process monitoring was initially introduced for welding beams with fixed optics. IPG has added functionality for applications that require joining of dissimilar materials and challenging non-ferrous alloys, where wobble- head welding is used to improve quality dramatically. Recent iterations of the LDD inline weld monitoring system are able to measure these increasingly sophisticated welding processes with exceptional detail. Tis technology provides the data manufacturers need to react to issues instantly, and save costly scrap. More recently, inline monitoring on scanner-based products has been introduced, enabling welding in a larger field of view for multiple parts or multiple welds per part. Tis combination is expected to have a huge impact on the fast-growing e-mobility sector. Te technology employed by the LDD weld
monitor is extremely versatile. Te system is able to resolve and measure pretty much anything that’s visible through the welding optics. Tis allows the
An LDD-equipped IPG mid-power scanner, used for single-mode wobble-spot welding of mixed materials (aluminium on copper). The LDD depth measurement (right, inset) shows the exact penetration of the weld. A short region of shallow penetration is marked in red. In production, this would cause an NOK message to be sent to the controller, and the part could be scrapped
same instrument to flexibly monitor different aspects of a process, ignoring those that aren’t relevant to a particular welding step and focusing on the critical metrics. Dramatically different processes can be run in quick succession, using the same head, and the different measurement modes, along with their respective quality limits, are activated and controlled using a single soſtware utility. New monitoring modes can be continually added in soſtware to advance the functionality of the system as production needs arise. Te result is a very complete picture of the weld quality for every part, which empowers manufacturers to make better decisions more quickly.
Te newly developed LDD weld monitor is
helping manufacturers by reducing scrap, by facilitating early detection of defective sub- assemblies, by providing more complete and accurate records for safety-critical applications than was previously possible, and by allowing QA procedures to be streamlined, saving time and operating costs.
Paul Webster founded Laser Depth Dynamics in 2012 and is CTO and general manager of IPG Photonics Canada. Chris Galbraith, originally an applications specialist at Laser Depth Dynamics, is applications manager of IPG Photonics Canada.
FOR HIGH POWER
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