Scan System Teaches Robots How to Take Aim

A new scan system called intelliWELD combines flexible industrial robots with high-dynamic scanners, enabling complex on-the-fly welding operations without sacrificing speed or accuracy.

Developed by Blackbird Robotersysteme GmbH, a division of Scanlab AG, the system is available for position-critical seams through a coaxial illumination unit and camera system.

Remote laser welding of galvanized steel surfaces requires the creation of a defined gap for degassing zinc. This time-intensive, costly preparatory step can be avoided by switching the alternative joint geometries.

“We wanted robot-based scanner welding’s advantages [of] high flexibility with maximum efficiency to also be made available for position-critical seams,” said Dr. Wolfgang Vogl, CEO of Blackbird. “The system’s intelligent control technology considers the robot’s motion path, and positions the scan mirrors in accordance with sensor data to enable not only complex welding operations, but also simultaneous correction of positioning inaccuracies during the motion sequence.”

The intelliWELD’s optical design features a two-port head that can serve as separate inputs and outputs for coaxial sensors. A prefocus optic is used in place of an objective to attain sharp camera imaging free of chromatic aberration throughout the entire working volume.

BMW’s industrial application of the scanner technology for Mini door fabrication drastically reduced process times, while seam tracking ensured robust and precise welding of front fillet seams.