As part of a new software release for edge tracking using optical coherence tomography (OCT), Blackbird is presenting a functional enhancement specifically for the complex requirements of modern welding applications. The solution can now be used in an even wider range of applications and has the ability to react to and communicate various error cases. The update thus supports flexible and customized welding processes and sets new standards for production automation.
The requirements for edge tracking with OCT have evolved dynamically. Originally designed in cooperation with OEMs as a solution for edge tracking of fillet welds on lap joints in the body-in-white area, Blackbird was confronted with the growing challenges of new joint geometries. These arose primarily due to the specific requirements of new fields of application, such as the agricultural and construction machinery sector. The OCT technology, which is facing increasingly complex requirements due to the growing market penetration of remote laser welding, impresses with its continuous adaptability in order to optimally support specific applications.
The functional scope of the Blackbird OCT solution has been significantly expanded with the new release and offers optimized edge tracking options for a variety of joint types that are in demand in modern welding applications. In addition to the proven edge tracking for fillet welds on lap joints, the system now also supports precise edge tracking for T-joints, corner joints, edge joints and butt joints. This means that a wide variety of components can be reliably welded with a single solution in future. Users can design their components independently of specific joint geometries and do not have to compromise on the precision and robustness of the process.
Recognize mistakes before they happen
Another option of the release is the integrated quality feedback parallel to edge tracking. Depending on the detected gap size, the system can react to ‘unsuitable’ welding conditions on a case-by-case basis. For example, the new function automatically deactivates the laser power or stops the welding program internally if defined boundary conditions are violated. These predefined reactions not only increase the safety and quality of the welding process, but also enable smooth integration into automated production lines and the implementation of targeted repair strategies.
The new functionalities are implemented from RSU software version 8.20.0 and enable the user to efficiently and precisely process a wide range of components on a production line.
Background
Blackbird Robotersysteme GmbH manufactures system solutions for remote laser welding with scan heads. The mirror-based beam deflection units can be seamlessly integrated into industrial production systems, especially robot cells. The company’s core competence is the development of powerful control technology, intuitive user software and supplementary process monitoring solutions. In combination with 2D and 3D scanning systems from its sister company Scanlab, Blackbird offers machine and plant manufacturers worldwide a wide range of highly efficient, pre-integrated solutions for series production in automotive manufacturing, electromobility and numerous other industries.