3D weld seam inspection with profile sensor
Profile sensors that output a height profile by means of laser triangulation are best suited for recording weld seams for their inspection. By moving the sensor or the component, the seam is completely recorded. The major advantages compared to imaging with conventional 2D cameras are the additional height information and reliable imaging despite different colouring and surface structure of the weld seam.
The V60 image processing software detects defects such as pores, holes, binding errors and weld spots in the 3D data obtained in this way.
The seam geometry is trained with a sample part. For the defect evaluation, only the tolerance in the Z-direction and the minimum error area must be defined as a threshold. The evaluation is done with a 3D pattern comparison.
The lean hardware concept consists of an evaluation computer and profile sensor with 24VDC power supply. The profile scanners are supplied with a calibration protocol. A test normal in the cell is used to check the calibration and position in relation to the robot TCP.