Welding Seam Inspection

The welding process is inherently complex due to differences in techniques and materials. As a result, weld inspection is a challenging process and defects (e.g. weld pits inspection) are difficult to detect.

For example, the accessibility and visibility of certain weld seams might limit the effectiveness of a visual inspection. Any inspection which relies on the skill and experience of an operator makes it susceptible to human error.

Fortunately, automated weld seam inspection systems aren’t susceptible to human error and don’t typically suffer visibility issues, as they rely on various measurement sensors. These sensors, which are typically laser displacement sensors or laser profilers, are extremely reliable and very precise.

Seam finding/tracking is a crucial application in the welding industry as it ensures accurate and consistent weld positioning, which is essential for structural integrity and strength. Additionally, seam finding/tracking allows for precise control of the welding process, including speed and heat input, yielding high-quality welds. Automatic seam tracking, finding, and guiding also saves time and reduces the need for manual labor, thus increasing overall production efficiency.

KEYENCE’s LJ-X8000 Series laser profiler contains the technology and capabilities to excel in this application. Unlike traditional vision tracking systems, the LJ-X8000 Series relies on direct height data rather than part contrast, making it more reliable and accurate. It can capture the whole part with just one sensor, utilizing both 2D and 3D position tracking. This feature allows the LJ-X to account for variations in part presentation, ensuring consistent and precise results.

Quality checking and bead appearance inspection are critical for ensuring weld integrity and meeting industry standards. Common weld failure points can result in costly rework or even safety hazards, making it essential to have accurate and reliable quality-checking methods.

Quality checking inspects the appearance of all weld beads, including dimensions such as throat thickness and leg length, undercuts, and blow holes. These measurements are crucial in verifying that the welding process is within the specified tolerances and meeting the required standards.

The LJ-X Series offers a highly efficient solution for quality checking through its automated inspection capabilities. By following the welding torch, it can inspect 100% of welding beads in real-time, providing immediate feedback on any defects like splatter, pits, slag or burn-through, or deviations from the desired dimensions. This allows for quick adjustments to be made and ensures that all welds meet the required standards.

One of the biggest advantages of using laser measurement technology like the LJ-X Series is its ability to measure directly without relying on part contrast. This eliminates potential errors caused by variations in part color or reflectivity, ensuring accurate and consistent measurements every time.