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.
Our Services Include:
Advice
We will provide you with the most detailed consulting on the full range of beam sources and on drafting and reviewing specifications and feasibility studies.
Procedure and Process Optimizations
Often the parameters for a laser manufacturing process are determined in the laboratory in advance. For an optimal processing efficiency these parameters must be optimized when preparing the series component. For this, 4D offers expert production support on site to minimize errors and create a secure process window through quality evaluation, and researching the causes of errors.
Training
The range of training offers doesn't just cover specific information for products sold by 4D, but also general training for the laser material processing. Training is provided at the customer’s site, in order to offer employees a training with the most practical relevance to their products. In the course of this training our colleagues explain the wide range of possible parameters for laser welding and provide training on concrete measures for process optimization.
Project Process and Management
As part of the project planning and coordination for new production installations, 4D offers a complete package, including drafting specifications, reviewing tenders, project management and machinery acceptance.
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.
References
Satisfied customers and suppliers are the best reference. In the following you will find a brief selection from the list of firms, with whom we have a successful and mutual business partnership.
4D Ingenieurgesellschaft für Technische Dienstleistungen mbH was founded in 1995 by Dr. Jens Mommsen and Dr. Martin Stürmer. The company is based in Isernhagen near the Hannover-Langenhagen airport. 4D provides a strong partnership in the fields of laser technology and laser material processing thanks to its years of experience. 4D develops, manufactures and distributes systems for the observation and monitoring of laser processes for the quality assurance.
The 4D strategy is consistently focussed on customer-oriented solutions. This is based on constant contact between the user and the developer, as well as the timely and expert handling of projects and commissions.
Quality Management
The basis of sustainable quality management and effective quality assurance for 4D is the ISO 9001. Customers, suppliers and partners alike acknowledge a quality management based on ISO 9001 as accredited evidence of capability and competence for a company. Furthermore, it represents a valuable tool for documentation of quality assurance and continuous improvement.
4D Ingenieurgesellschaft für Technische Dienstleistungen GmbH, based in Isernhagen near Hanover, develops, manufactures and distributes systems for the observation and monitoring of laser processes for quality assurance. The main area of application of these QA-systems is laser welding in vehicle manufacture, automotive products and the electronics industry. Our customers include well-known firms in Europe, America and Asia. With its focus on laser technology 4D works in an industry of the future.
Tips for Applications
Would you like to reshape your future career? You can find tips for applying to 4D here.
Which positions are waiting for you
Our open positions listed below give you an up-to-date overview of the areas, in which we are currently looking for new colleagues. If some job vacancies are shown there for a longer period, it is possible that there are multiple positions to be filled.
We also look forward to initiative applications, which do not relate to our current advertisements.
We look forward to your digital application folders, including a c/v and your certificates. We would be happy to hear about your salary expectations and your earliest possible start date in your application, as well as receiving information about your motivations.
Feedback
We will be in contact with you promptly.
Data Protection
Your application will be handled in confidence. All data is stored securely and only for the purpose of the application. The storage period is 6 months – unless would like to remain in our applicant pool for longer, or not at all.
If you do not wish your data to be stored, please indicate that in your application.
What we offer
We are a motivated team in an area of business focussed on the future with an international field of activity. Our collaboration is characterized by a flat hierarchy and collegial interaction. You can look forward to technical challenges and a creative working environment with us, in which the individual responsibility of our staff is highly valued.
