研究目的
To develop an innovative system for remote-laser welding that enables in-line adaptive 3D seam tracking and laser power control to address the challenges of small series and user-customized manufacturing, including thermal deformations during welding.
研究成果
The developed system for simultaneous 3D seam tracking and laser power control in remote laser welding achieved positioning tolerances of under 0.02 mm with a deviation of 0.06 mm, which is better than the resolution of the human eye. The system enables shorter teaching times and stable welding during the whole welding process, even with simple clamping devices.
研究不足
Further improvements are needed for the detection of different seam types and for RLWS with higher nominal laser powers. The system's performance with thicker materials and higher laser powers needs to be investigated.
1:Experimental Design and Method Selection:
The system consists of an industrial robot, a scanning head with optical triangulation feedback, and a fiber laser. The methodology involves detecting the keyhole and its shape and size on the acquired image, extrapolating the detected seam curve to the nearest point relative to the keyhole, and calculating the new laser position and power.
2:Sample Selection and Data Sources:
Commercially available 304 stainless steel plates with dimensions 300 mm x 30 mm were used for validation purposes.
3:List of Experimental Equipment and Materials:
Industrial robot (Yaskawa MC2000), scanning head (HighYag, RLSK) with a console attached camera (PointGrey, Flea3, model FL3-U3-13Y3M-C), fiber laser (IPG, YRL-400-AC, 400 W), illumination laser (Fotona XD-2, 810 nm ± 10 nm), bandpass filter (Thorlabs, FBH810-10).
4:0). Experimental Procedures and Operational Workflow:
4. Experimental Procedures and Operational Workflow: The system was tested on a curved flat edge seam and a 2.0 mm thick lap joint. The welding velocity was set to 100 cm/min for seam tracking validation and 60 cm/min for power control validation. Camera frame rate was set to 80 frames per second.
5:0 mm thick lap joint. The welding velocity was set to 100 cm/min for seam tracking validation and 60 cm/min for power control validation. Camera frame rate was set to 80 frames per second. Data Analysis Methods:
5. Data Analysis Methods: The keyhole location and shape were determined using image processing techniques, including Gaussian filtering and morphological operations. A PI controller was used for laser power control.
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illumination laser
XD-2
Fotona
Equalizing the brightness of the keyhole and surrounding area
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bandpass filter
FBH810-10
Thorlabs
Improving the visibility of the seam
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fiber laser
YRL-400-AC
IPG
Welding
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industrial robot
MC2000
Yaskawa
Rough positioning of the laser beam
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scanning head
RLSK
HighYag
Precise laser beam movement
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camera
FL3-U3-13Y3M-C
PointGrey
Monitoring the seam position and the interaction zone between the laser beam and the workpiece
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