In the automotive industry with laser welding technology early and has achieved mass production of the plate for the range of laser Welding Electrode Material. Soudronic Automotive Systems, Inc. (hereinafter referred to as "Soudronic") Department of the world's leading laser welding equipment and system suppliers. According to statistics, in 2004 the global production of tailored blanks for the 180 million expected in 2005 will increase rose to 250 million. As the laser weld quality tailor welded blanks for particularly demanding, therefore, Soudronic earlier developed a laser-based optical imaging and sensing technology for tailor welded blank weld quality control of the first generation of online real-time monitoring system, and the system applied to the laser welding equipment and laser welded pipe equipment. The system uses greatly improved Soudronic in the field of laser welding technology, competitiveness, with TWB suppliers and car manufacturers continue to exchange, Soudronic developed a new generation of more simple and reliable visual seam quality testing system - "SOUVIS (r) 5000" (SOUdronic VIsion System). As the double-edge technical features of the system unique and outstanding detection performance can be widely used in automobile manufacturing industry, laser welding, laser welding, such as car body in white and laser brazing and fuel injection systems and transmission gear welding. Welding process and its technical limitations In industrial applications, the laser welding process control is critical, mainly because: The accuracy of the workpiece to be welded, welded workpiece clamping accuracy positioning and repeat a certain limit, the gap before welding must be controlled within a certain accuracy; for some form of surface welding, laser welding focal point to track the trajectory of the gap (length up to 2m above) the accuracy of laser beam diameter does not exceed 10%; sometimes have to be welded metal surface coating (eg galvanized steel), (tag: tungsten wire cutter) and the metal coating due to its low melting point materials are often resulting weld porosity. Mass production in automotive industry applications, laser welding and more use of "deep welded" or "transparent welding" process. However, even on the seam gap control, no matter how, it can not avoid welding defects. From the surface, the laser engraving machine can weld defects, mainly divided into two categories: surface defects and weld geometry of random defects, the former general observation by a weld can be found, which point out that the unpredictable position of local defects. "SOUVIS (r) 5000" The image processing system "SOUVIS (r) 5000" The hardware platform is a powerful industrial PC with built-in image processing system with real-time operating system. Sensor head for a CMOS camera, camera features and special adaptive feedback flash technology. The system can be integrated into the TCP / IP network for data exchange, but also by bus (CAN, INTERBUS) connected to the PLC for external control. The system can also connect with a remote server, remote quality control and system failure self-diagnosis. Image processing computer system can achieve direct control of some functions (I / O''s). Image acquisition Two other pieces by the laser line projected to be at a certain angle to get onto the weld seam detection of three-dimensional data, that the weld surface geometry data. In a flash device while continuing 20μs instant flash, CMOS camera shot of the weld zone to be detected duplex photos. The two ways to obtain the maximum contrast in the image, the camera features both adaptive optics can also be set using special software, so the system eventually obtain a single image to be detected in the weld zone is reflected in all of the information . System to obtain the standard image size of 10 mm × 10 mm, a resolution of 10μm. In the actual production process, the sensor head or to be detected in a continuous movement of the workpiece to be taken as the system as the trigger device can take to ensure a continuous take, like the two adjacent images have some overlap, in order to achieve continuous take, like testing. Limited by the speed camera and take as data transmission speed, the system detects the speed of 30m/min. Because the system and take the test as fast, so in practice, affect the detection rate of the bottleneck is often the other production equipment, such as welding robots, workpiece shuttle devices. Feature extraction analysis of weld Laser welding of weld quality testing depends primarily on two data characteristics: surface of the weld geometry measurements and the absolute uniformity of the weld surface. Weld seam strength of local defects and the surface will affect the visual appearance, therefore, "SOUVIS (r) 5000" use the following three ways simultaneously detect local defects weld: weld-shaped surface three-dimensional data analysis, the organizational structure of the weld analysis and pinhole analysis. The organizational structure of the weld through a decisive general, random, non-homogeneous fibrous structure to reflect that "fish-bone-shaped" structure. In order to analyze the structure of the weld, the slope of the system based on fiber structure, direction and multi-pixel approach to generate the Welding Electrodes Manufacturers In China. These structural features can be just a handful of figures to reflect the quality of the weld surface uniformity and smoothness characteristics. If the weld zone in each of these structural features of the data vary widely, then a partial seam weld defects, such as protection because the plasma caused by melting or burning less depth because the surface coating or weld porosity caused by pit. Small weld defects (such as pinholes) can not be detected by this method, therefore, the system uses the first three kinds of analysis algorithms to detect less than a few hundred μm, small welding defects, such as laser-brazing weld in diameter on the detection of only 200μm pinhole, this method is known as the pinhole analysis. Conclusion Welding quality with simultaneous visual monitoring in the field of 10 years of experience, Soudronic developed a unique technology, "SOUVIS (r) 5000" weld quality on-line real-time monitoring system for the detection of laser brazing welding or laser weld quality . As a result of high-resolution laser sensor with the μm-level access as technology, the system has excellent detection and resolution capabilities. The whole system integrated in a single unit, to facilitate its installation on the welding equipment, and through a remote server system fault diagnosis. (Tag: seamless pipe) the online real-time monitoring system has a user-friendly, requires less set the parameters, simple operation, etc., while the system hardware rugged shop environment can fully meet the three classes of continuous production.
First, the project or the use of more representative forms of welding joint test, to determine the best methods of operation and Welding Electrode Materials, welding procedure test solely responsible for the welding laboratory. Second, the structural assembly of tacking 1, positioning the assembly before welding, welding groove and the inside and outside the range of 20mm on each side of the oil must be solvent wiping clean, and polished with a hand grinder to remove rust, oxide and other impurities, the exposed surface of base metal welded pieces of metal gloss. 2, positioning welding welding work as welder must hold certification in welding. 3, the assembly quality and meet the technical requirements before drawing positioning welding (such as the need for warm-up before welding the weld, it must be preheated to a temperature required to locate only after welding.), Positioning welding electrodes used (subject to drying dry treatment), the wire must be used when welding seam welding consumables formally consistent positioning of the weld should be filled crater. 4, positioning the weld length is generally 20-50mm, pitch length of 400-600mm, fillet weld leg size no larger than half the size of the design, and should not be greater than 8mm, should be positioned away from the weld seam end 30mm above the design . (Except in exceptional circumstances) 5, the positioning of the weld shall not have cracks, without excessive slag, porosity and other defects, such as welding defects are found, must be thoroughly cleaned, re-tacking. 6, the weld seam intersections and sharp changes in direction at the weld may not have positioning, positioning the weld should be left there for more than 50mm. Third, the general provisions of welding 1, as this project must be certified welding welder welders and passing the examination should be specially trained (training assessment for this project). 2, as a welder welding should be familiar with the project technical documentation and construction process requirements, and must be strictly in accordance with welding procedure specifications required by the welding parameters, welding sequence, the direction of welding welding. 3, in order to prevent the components in the welding process produced a large amount of deformation, welding pieces must be placed flat, does not allow casual place for welding, and should be strictly in accordance with the provisions of the welding sequence, the direction of welding welding. 4, should be carefully checked before welding welding groove meets the requirements, and should pay the welding groove and near water, oil, rust, oxide and other impurities thoroughly cleaned before welding. 5, preheat and post weld heat requirements, in strict accordance with the provisions of welding preheat temperature, preheat range, after the heat temperature and time to do warm-up before welding, thermal relaxation after cold working. Welding preheat requirements, the lowest level (Road) preheat temperature between a temperature not less than the channel, the highest level of all welds (Road) between the temperature should be ≤ 250 ℃. 6, before welding on scrap board tested by an official before allowing welding current in welding products. 7, the welding power supply ground wire should be fastened with the base metal weldments, to ensure good contact. 8, the arc should be in the arc welding groove boards, or within, does not allow any damage to the workpiece surface, the base metal arc. 9, welding should pay attention to the starting spot weld, solder and weld the end of the joints does not produce welding defects, welding multi-channel multi-layer, each layer (channel) for welding at the joints should be staggered, each After a welded seam, must be slag, spatter and other impurities, clean, and carefully check the weld quality, confirmed that no defects, then under a welding seam. (If it is found defective weld before said, it must be thoroughly cleaned before welding defects allowed to continue welding.) 10, the plate fillet weld, the weld around the ends must be welded corners. 11, the welding "submerged arc welding" is, in principle, allow the cut in the arc welding process. If for some reason in the welding process occurred off the arc, the weld should be 50mm above the plane to end, and where the use of hand-held grinding machine grinding into a gentle slope like to be allowed to continue Welding Electrodes . 12, the welding "arc welding", the required gas flow should be good to debug, and aspirated about half a minute, put a clean air emissions within the pipeline, before allowing welding on weldment. 13, the "arc gouging" clean weld root, the gouging tool to focus on wind, air pressure should ensure that there are 0.39-0.6MPa, and based on carbon rod diameter, thickness tested by weldment current gouging, gouging process should avoid "carbon folder" and "James Jardine" phenomenon. After clean-gouging, shavings must be removed and hand-held grinding machine to gouge exposed metallic luster after polishing to allow welding. 14, the welding is completed, the surface of the slag should weld spatter and other impurities, clean up, carefully check the quality of the weld appearance, and marked at the required mark welders, and turn order tests (including full-time appearance and internal quality check). 15, welded joints when welding defects occur, are not allowed to handle, should be timely analysis to identify the reasons, according to the rework process and the technical staff in the field under the guidance of welding defects before processing. 16, the workpiece on the board and leads arc flame cutting board to remove the application, is strictly prohibited hammer down.