Efficient implementation of laser welding automation using modern measurement technology

Ensuring the integrity and quality of the welded hair clip is crucial in the assembly of electric motors. Usually, 160 to 220 hair clips are welded to each motor, and the accuracy of these welds directly affects the overall quality of the stator and motor. The traditional method of detecting these welds is difficult to balance the requirements of safety and accuracy, which often leads to damage to motor performance.

challenge
The main challenge is to develop a system that can ensure stable and high-quality laser welding processes. Any deviation in the weld seam can lead to motor failure, resulting in serious production delays and increased costs due to parts rework or scrapping.

The image processing system models complex relationships during the welding process, which are difficult to capture using traditional rule-based methods. By analyzing the deviation from the optimal weld characteristics, the system can also gain a deeper understanding of potential issues in upstream process steps.

application
ZScan 360 is deployed as an online measurement system on production lines for stators and other rotating symmetric components. Its functions include:
High resolution data acquisition: The 3D scanner provides detailed images of each welding point to ensure the detection of small defects.
Real time analysis: Deep learning algorithms process data in real-time and can immediately identify and correct any welding defects.
Process optimization: The system can not only perform inspections, but also provide feedback to improve upstream processes, ensuring overall production quality is improved.

benefit
Improving accuracy and safety: The detection driven by artificial intelligence ensures that each weld seam is accurately evaluated, thereby reducing the risk of motor failure.
Efficiency and automation: The automation of the testing process means faster and more reliable quality control, reducing manual intervention.
Cost saving: By minimizing defects and rework requirements, this system helps to reduce production costs and increase output.

conclusion
Senswork's 3D detection system integrates artificial intelligence, representing a significant advancement in the automation of laser welding processes. By ensuring high-quality welding and providing actionable insights for process improvement, it can help manufacturers maintain high standards while optimizing efficiency and reducing costs. This solution demonstrates how to utilize modern measurement technology and artificial intelligence to address complex manufacturing challenges and improve quality inspection efficiency.

Source: Laser Net