WeldWatcher: Quality Assurance in the Laser Material Processing
The 4D WeldWatcher is best suited as a reliable and complete solution for quality control in laser welding, cutting and brazing. This online monitoring system is used in many areas of industrial production:
Automobile construction
Automotive
Power generation technology
Electrical engineering
Aviation
System construction
Consumer goods
WeldWatcher Technology
Technical Components:
19″ industrial PC
Windows 7 or Windows 10 operating system
One line interface (only one sensor cable up to 75 m in length)
Programmable sensor
One sensor system (no space required at the optics)
Automatic operation and set-up operation for process optimization
Application-specific evaluation algorithms
Direct, observable visualization of the results
Long-term data storage
PLC interfaces (configurable)
Server/client operation
Additional Functions:
Protective glass monitoring
Automatic data transfer for operational data recording
Display of all results for a component at reworking stations
Back-up/emergency laser operation
Automatic adjustment at the various processing steps of a system (welding, smoothing)
Evaluation for pulsed welds
Database requests for the error status of a sub-assembly
The WeldWatcher Advantages
Sensors
Fast and easy installation, no adjustment required
No system rebuilding required
Standard adapter in the laser with manufacturer approval, partially retro-fittable
One sensor per laser is sufficient, also at multiple processing stations
No sensors in the welding area for the optics, no risk of collision
Automatic setting (for a range of welding operations)
Data Transfer / Signal Connection
Error and interference storage with state messages
Time stamps, error classes, warning limits, subsequent defects
System Security
Database (FIFO)
Data transfer tools for the central server / MDE / BDE
Standardized interfaces for system management
Software / User Interface
User-friendly, clear user interface under Windows
Color display of the seam positions and errors (welding group)
A range of access levels with a staged password protection
Automatic switching for components / welding stations
A range of languages
System Upkeep / Maintenance / Costs
Maintenance-free sensors (no protective glass replacement, no adjustment)
No complex image-processing software required
Automatic calibration and training
Fast commissioning, low follow-up costs
Remote maintenance option
Special Applications
Laser Brazing
For laser brazing the process monitoring with WeldWatcher includes the combined evaluation of process radiation and wire feeding. Faults, such as height and lateral misalignment, wire supply faults or volume and geometric deviations can be identified immediately and notified to the system controller.
Laser Cutting
During laser cutting the puncture process and the subsequent cut are monitored and evaluated and system faults are identified.
Pulsed Welds
A further major area of application for the WeldWatcher is the monitoring of pulsed welds. The requirement for a visual component inspection lies in the large number of pieces for brief weld durations. The WeldWatcher enables a fast and automatic monitoring of each individual pulse (single welding) or a series of pulses (burst). Through this, it is possible to immediately identify material and location deviations of the joining partners and process-related welding errors.
Combination Processes
The WeldWatcher can also be used for the process monitoring in laser combination processes, such as hybrid welding. It is also suitable for varying monitoring tasks. Through its programmable sensors, which can be automatically adjusted within a few milliseconds, it becomes possible, for example, to switch from deep welding to downstream smoothing welding.
Remote Welding
Welding with scanner systems provides an additional alternative to the traditionally used process for bodywork or sheet metal processing.
Industry Sectors
The WeldWatcher is highly versatile and can be used in all industry sectors. Whether for laser welding, laser material processing, diode lasers or fiber lasers, the WeldWatcher monitors all laser processing stations involved in welding, brazing or cutting. To do so usually one WeldWatcher per laser is enough – even for monitoring hundreds of seams or points.
Areas of application include automotive parts for suppliers to the automotive industry, e.g. manufacturers of car seats, airbags, body components or vehicle electronics. The 4D WeldWatcher is commonly used for the quality monitoring for components and electric motors used in consumer goods and electronics manufacturing.
