Trumpf laser uses artificial intelligence technology to improve welding quality

At last month’s LASER World of Photonics exhibition in Munich, Germany, industrial solutions and laser giant Trumpf presented a new materials processing laser system solution specified to improve welding processes.

The system combines several sensors that monitor all process steps during laser welding. An integrated AI quality control system checks the weld seams, for example, and OCT (optical coherence tomography) monitors the welding depth of the laser.

Solution for laser welding

Martin Stambke, Product Manager, explained, “Our solution is unique on the market. We are offering all components, such as the beam source, sensors, and optics, from a single source. We also take care of installation, service, and programming of the system, which is tailored to a user.”

The new solution enables users to weld precision components that must be free of defects, such as batteries for electric cars or hairpins for electric motors. To ensure flawless weld seams, the user must set the optimum working distance between the various components and the laser. This is enabled by the programmable PFO 33 focusing optics, which can adjust the focus position of the laser independently.

‘2.5D mode’
“This so-called 2.5D mode is more cost-effective in many applications than 3D mode, in which the PFO can still move up and down during the welding process. This is because less complex controls and programming, as well as fewer moving axes, reduce acquisition, operating, and maintenance costs for the user,” said Stambke.

“In addition, it is faster for the optics to adjust the focus position themselves than to move the entire optics up and down in the laser cell. Our solution is therefore cost-efficient, yet powerful,” he said.

Better weld seam quality from the very first component With integrated optical coherence tomography (OCT), users can not only monitor the welding depth of the laser, but also check the distance between the laser and the component.

“This ensures the focus position of the laser and prevents welding errors,” said Stambke. “Moreover, VisionLine Inspect is used to check the quality of the manufactured components. A camera takes a picture of the weld seam and the system uses AI to detect any potential errors. By combining AI preprocessing and conventional algorithms, we are creating traceability and transparency.”

Source: optics.org