Optical Seam Tracking Manages Critical Welding Concerns

In an automated world where manufacturing processes are getting faster, part tolerances are growing larger, and material fit-up inaccuracies are increasing, compensating for these process issues is an increasingly critical concern. In Booth B-17044, ABB Robotics (Auburn Hills, MI) provides 2.5D or 6D optical seam tracking as a software option to manage these issues. The 2.5D optical sensors have one laser stripe to measure Y and Z and orientation around X. The 6D optical sensors utilize three laser stripes to measure both joint position (X, Y, Z) and orientation (three Euler angles). Whether a 2.5D or 6D is used, the laser-based optical triangulation sensors perform a non-contact measurement of the joint profile, refine the garnered joint information and then forward the joint information to the robot, resulting in the necessary weld path corrections on-the-fly.

In addition to providing weld path corrections, optical tracking sensors can also send additional joint information to the ABB welding robot, providing the end user with numerous process benefits that include on-the-fly adjustments to weld travel speed, wire feed speed, and weave shape and size. With the power of an IRC5 robot controller coupled with its path accuracy, the optical seam tracking option is able to update the welding path in milliseconds with an accuracy in Y and Z of ± 0.2 mm (straight seam). This optical seam tracking can also be performed simultaneously with two robots and a 3-axis positioner, welding and weaving in a MultiMove configuration, an IRC5 software option that allows up to four robots to work together, along with workpiece positioners or other devices, in fully-coordinated operation.

ABB Robotics, 1250 Brown Road, Auburn Hills, MI 48326, 248-391-9000, new.abb.com/products/robotics.