Precitec is now offering a new complete solution for wire-guided joining processes. The “Scansonic ALO3” is a brazing/welding head with a fully integrated coaxial quality monitoring system. The system requires no additional space and gives users the cutting edge performance of Precitec products. Seam geometry monitoring detects the profile and the position of the fillet welds on the lap joint and double-flanged seams on the butt joint.
Fixture mechanisms can be optimally matched to the welding results, irrespective of any additional quality monitoring components. The welding head causes no obstruction whatsoever in the processing area and can easily travel in and out between the fixture mechanisms. The camera required for quality monitoring is integrated directly into the head.
Profile measurement takes place a few millimetres behind the welding spot, necessitating only a minimal overrun at the seam end, with practically no cycle time loss. Frequent weld defects like lack of fusion, the wrong positioning of wire on the upper/lower metal surfaces and gaps between the metal sheets can now be reliably identified and monitored. The system also recognises open pores of 0.5 mm and upwards. Monitoring takes place during welding, i.e. errors are practically recorded and analysed in realtime. Application examples here are the brazing of vehicle body parts and the welding of aluminium with an additional wire.
The “ALO3 head” with built-in quality monitoring can be easily integrated into all brazing and welding systems, and no modifications have to be made when retrofitting existing systems. Seam guidance is both precise and wear-free. It takes place in the Tool Center Point and is carried out by means of lateral and vertical probe movements of the additional wire, enabling the welding spot to smoothly follow small radii and 3D contours. Continuously variable force ensures that the wire is securely placed on the leading seam edge at all times.
This solution takes a decisive step towards zero-defect production.