• Profile sensors enable precise seam placement in robotic welding cells

Profile sensors enable precise seam placement in robotic welding cells

Automatic seam tracking in robotic welding cells is a complex task in harsh industrial environments.The detection of guide points with different types of joints with micron-level accuracy by means of 2D/3D profile sensors is one of the most effective solutions to this challenge.Combined with wenglor’s uniVision software, the new weCat3D MLZL 2D/3D profile sensor not only combines the necessary accuracy and profile quality, but also offers easy installation, integration, robustness and user-friendliness.
The MLZL’s slender housing with integrated cooling and flushing functions can be easily and space-saving mounted directly on the welding torch.Due to the housing dimensions of only 33 × 183 × 69.8 mm, the robot can also work in tight corners.
“The MLZL 2D/3D profile sensor does not require any additional protective housing and does not require tilting for alignment,” explains Dr. Sascha Reinhardt, Product Manager at wenglor.”The design also provides adequate protection against weld spatter and interference with ambient light.” Despite the harsh industrial environment, the weld sensor provides high-quality profiles for accurate joint detection.Optional red or blue lasers are available, and users can choose from three laser classes: 2M, 3R, or 3B.”The MLZL relies on the advanced laser technology of the weCat3D series and thus provides excellent contour quality for optical seam tracking,” says Dr. Reinhardt.”The sensor has been specially adapted and optimized for the high demands of welding robots, especially for the complex task of optical tracking of the weld seam – both in terms of hardware and software.”
Wenglor engineers tested and developed special triangulation sensors together with customers in the welding industry as part of the Early Adopter Program (EAP).Feedback and expertise gathered from this program eventually flowed into MLZL.“We were able to incorporate a lot of hands-on experience directly into the development, resulting in extremely precise information ahead of time on what is important in automating the welding process, the biggest obstacles users face, and what their aspirations are.”
In its current update 2.5.0, the configurable standard software uniVision receives a separate module dedicated to seam tracking.For users, this means setting up a welding application with just a few clicks.”With the help of powerful algorithms, tracking points can be determined reliably even in the event of failure of the joint route (e.g. fiducials). Predefined templates save all common joint types and significantly reduce configuration work,” explains Dr. Reinhardt road.The results can then be visualized on a web-based basis.Robot control systems and their software from KUKA, Fanuc, ABB, Kawasaki and Yaskawa directly integrate multiple interfaces to implement welding processes with less effort, more functionality and better results.
The new combination of software and hardware provides each user with a flexible welding solution that can differentiate applications with or without robot integration.The most convenient and comprehensive system consists of sensors, control unit with pre-installed uniVision software application and optional robot interface.”For this purpose, the system was developed as a complete solution as part of the EAP. However, there are also other combinations, with or without a control unit and customer-specific integration software, which means that we can offer the right solution for each customer’s needs program,” Dr. Reinhardt continued.
The parameterizable uniVision standard software is used to analyze images and height profiles in the field of industrial image processing.It is also possible to evaluate 2D and 3D data from smart cameras, vision systems, smart 2D/3D profile sensors and IPCs (Control Units) with 2D/3D profile sensors.In total, the user can use up to 25 different software modules and different templates, depending on the selected hardware.
Compact housing (33 × 183 × 69.8 mm) Robust design with high IP67 protection class High profile quality (1,280 points per profile) Large working range from 74 to 158 mm X measuring range from 39 to 62 mm Integrated cooling and flushing Laser class 2M , 3R or 3B Red or blue light Special uniVision software module for seam tracking Robot interface for ABB, Fanuc, Kuka, Yaskawa and Kawasaki Industrial interface PROFINET and EtherNet/IP for easy integration into the control
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Post time: Jul-05-2022