Working in collaboration with CRC-Evans Pipeline International (Houston, USA), engineers at Meta Vision Systems (Eynsham, UK) have developed a Smart Laser Sensor (SLS) for automating arc welding equipment and robot welders.
The SLS -- which consists of a CMOS megapixel image sensor with an on-board FPGA and a DSP inside the sensor head -- measures changes in the geometry and position of the pipeline joints to be welded in real time.
The data is sent via an Ethernet or CANbus interface to a motion control system driving the external welding system, ensuring that the welding electrodes are always positioned correctly.
As the SLS measures 3-D profiles, it can be used to inspect the bevel on pipe ends as well as the weld bead after it is laid.
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The company claims that installing the SLS at least halves the cost of automating arc welding equipment and robot welders, compared with conventional laser sensors.
While CRC-Evans Pipeline International has worldwide exclusive rights to use the product for pipeline welding and inspection, Meta Vision Systems will be servicing demand for the sensor in all other markets.
More details on the sensor can be found here.
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Schramberg, Germany -- Leading laser system manufacturer Trumpf is integrating vision technology into some of its laser welding machines to improve flexibility and accuracy and speed up the system output.
Laser welding is employed for precise joining of components, often of different materials, in a number of industries: automotive infrastructure and components, medicaldevices, shipbuilding, aircraft, and engine turbines.
Trumpf chose to integrate vision sensor technology from Cognex Corp. into the programmable focus optic (PFO) in some of its laser welding machines, to enable automatic positioning to match workpiece position and size and determine coordinate transformation data. Instead of using grey-shade correlation, software images the geometric structures of objects (edges, dimensions, shapes, angles, curves, shading) and compares them to the real-time image to locate the object. In standard applications, complete image evaluation takes ~180 msec. Images and coordinate data are transferred via Ethernet to the laser's FDP server. The vision system integrates with the laser server's fault diagnosis using WinLas software.
The vision system eliminates the need for clamping and positioning devices, as well as an image processing PC. The system can be mounted straight onto the PFO to save space. Waste and production costs are also reduced, according to the companies. They vision-enables systems are also user-friendly for operators without prior vision experience.
Trumpf has more than ten systems in the field with the new vision system, all of which are retrofits or beta systems. In addition, potential new customers can send sample parts to Trumpf and integration partner Rohwedder AG Vision, to determine viability of the project (system reliability, aiming accuracy and μm tolerance, etc.) and test under production conditions.
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