Product category:
Seam-tracking, guidance systems
News Release from: Cognex UK | Subject: CNC laser welding - vision seam tracking
Edited by the Manufacturingtalk Editorial
Team on 05 June 2007
CNC laser welders assisted by advanced
vision
A high-performance family of vision sensors were chosen by a German builder of CNC laser profiling systems for an independent vision system with robust hardware conforming to IP67 (NMEA 6).
Trumpf Laser company, based in Schramberg, Germany, develops and manufactures machines and systems equipped with solid-state lasers These are then deployed in sectors such as automotive or medical technology
This article was originally published on Manufacturingtalk on 28 May 2001 at 8.00am (UK)
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One particular industrial application area is precision welding of small components made of different metals.
Trumpf decided to integrate vision technology into the scanner optic for welding on their laser machines.
This is known as the PFO (programmable focus optic).
Further reading
Complex vision technology in an affordable unit
Cognex have introduced the In-Sight 2000, an entirely new type of industrial machine vision sensor at a cost usually associated with "smart cameras"
Vision systems retrofitted like CNC
Special purpose machine tools and assembly systems, with Cognex machine vision systems as an integral part, are being supplied to the automotive industry by Douglas Curtis Machine Tools
Vision system dedicated to electronic production
Cognex has introduced Display Inspect - a machine vision software and hardware package for inspecting displays, keypads, and enclosures on LCD and LED display-based products.
Their objective was to improve flexibility and accuracy as well as speeding up the production process for their clients.
* Vision technology - integrating a vision system was a strategic development decision.
Vision would make it possible to automatically adapt the welding position to match each work piece position and size without operator intervention.
The vision system would determine coordinate transformation data and would also need to be user-friendly for operators without prior vision experience.
Any existing welding systems needed to be retrofitted without causing problems to the newly integrated vision system.
Trumpf wanted to concentrate on their core business while integrating vision technology effectively with simple installation for their customers.
Trumpf decided to work with Rohwedder AG Vision Technology, a company based in Markdorf, Germany, with a staff of experienced vision specialists.
The company is also one of Cognex' Partner System Integrators (PSI).
Therefore, end-users can be sure of receiving long-term technical support thanks to the established Cognex global network.
* Mechanics eliminated - more space, reduced waste and increased production - the high-performance In-Sight 5100 family vision sensors were chosen as an independent vision system with robust hardware conforming to IP67 (NMEA 6).
The In-Sight 5400 is used for more demanding requirements.
Their compact design means that the In-Sight can be mounted straight onto the PFO, thus saving space By deploying vision technology in their machines, Trumpf have eliminated the need for clamping and positioning devices.
The precise fastening of parts relative to the laser are no longer needed, or they can be much simpler in design thanks to the ability of the vision sensors to find small parts.
This means a new flexibility in the operating method, with increased automation and a significant boost in production quality.
Waste is reduced and production costs are cut.
* PatMax - rapid image evaluation and object location - instead of grey-shade correlation, PatMax vision software from Cognex uses the geometric structures of objects such as edges, dimensions, shapes, angles, curves and shading to localise their form.
The three-dimensional relationships between these central features of the acquired image are compared with the real-time image.
Data analysis allows the laser to accurately locate the object.
For standard applications the response time for a complete image evaluation is roughly 180ms.
* User-friendly communication - images and coordinate data are gathered by In-Sight and transferred via Ethernet to the laser's FDP server.
In-Sight dispenses with the need for an image processing PC and the system solution excels on account of its flexibility.
A key advantage of this vision solution is the In-Sight Explorer development environment.
Based on the Microsoft Windows XP operator interface, the tools in this software package means easier programming intervention and easier integration of the vision system to the laser server's fault diagnosis using WinLas software.
* Integrated vision technology - a proven success - the procedure has been designed in such a way that a potential client can quickly receive a detailed feasibility study on his application.
The user sends some sample parts to both Trumpf Laser and Rohwedder AG Vision Technology with user requirements.
Both companies work to determine the viability of the project.
The customer is assured of system reliability, aiming accuracy and um tolerance, as well as that the system operator will be able to handle the system without any prior vision experience.
The laser production system with the vision solution is then tested by Trumpf under production conditions allowing the subsequent installation and production start-up at the customer's to be implemented quickly.
More than ten PFOs with integrated vision in diverse industrial sectors are already in use.
All these system deployments - before official operation - were retrofits or beta systems.
Retrofits, in particular, with their backward compatibility to previously installed PFOs have demonstrated positive results as a 'Plug and Play' system.
A major advantage for future customers is now the proven success of PFOs with integrated vision systems. Request a free brochure from Cognex UK ...
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