Welding inspections - Import export

Initial Situation: Inspection of a laser weld seam for pores and geometrical anomalies The production of a client in automotive industry is subjected to extremely stringent quality requirements. This is valid particularly also for the precision of laser weld seam of fine mechanical work. 100% inline supervision is required for the following task: A laser weld beam (width ca. 200µm) has to be verified with respect to the presence of pores and geometrical anomalies. Camera inspection performed until now turned out to be not stable. Therefore the client is forced to implement an improved monitoring process. The challenge The resolution required amounts to 4µm. The high gloss finished material and glossy laser weld seam may give rise to reflections, and the space for installation is restricted. A low form factor for the monitoring equipment is imperative.

Rotationally symmetrical driving gears in a line producing for automotive industry are mutually connected by electron beam welding. The camera inspection carried out until was not able to assess the quality of the weld seams at the required precision. Non-contact laser measurement system Particular Challenge: As the welding seams show a high reflectivity and are located at a position hard to access, inspection is difficult, all the more so as they dispose of a width of only 500µm. Therefore it is quite a challenge for the laser measurement system. The QuellTech solution: A QuellTech Laser Scanner Q4-5 with extremely small shape factor and high resolution proved to be perfectly suited for this application. In order to suppress reflections from elements in the surroundings, a particular algorithm has been integrated. Furthermore, this laser measurement system features a particularly adapted laser wavelength and an ultrafine laser line.

• The mesh visor is made of galvanized wire cloth • It shields the face against radiant heat • The mesh visor has a window opening for lenses with the dimensions 60 x 120 mm • Among others, blue inspection glasses, green welding glasses, or clear glasses can be utilized in the window opening • The lenses are securely clamped in the lens frame by two steel springs • Like the other face shields, the mesh visors are also attached to an aluminium hard hat bracket (e.g. GFKHH003) • The blackened inner side ensures good visibility and prevents the wearer from being blinded by glare

• The mesh visor is made of galvanized wire cloth • From the outside the mesh visor is covered with aluminised fabric • It shields the face against radiant heat • The mesh visor has a window opening for lenses with the dimensions 60 x 120mm • Among others, blue inspection glasses, green welding glasses, or clear glasses can be utilized in the window opening • The lenses are securely clamped in the lens frame by two steel springs • Like the other face shields, the mesh visors are also attached to an aluminium hard hat bracket (e.g. GFKHH003) • The blackened inner side ensures good visibility and prevents the wearer from being blinded by glare

• The mesh visor is made of galvanized wire cloth • From the outside the mesh visor is covered with aluminised fabric • It shields the face against radiant heat • The mesh visor has a window opening for lenses with the dimensions 60 x 120mm • Among others, blue inspection glasses, green welding glasses, or clear glasses can be utilized in the window opening • The lenses are securely clamped in the lens frame by two steel springs • Like the other face shields, the mesh visors are also attached to an aluminium hard hat bracket (e.g. GFKHH003) • The blackened inner side ensures good visibility and prevents the wearer from being blinded by glare

This extremely robust flat-panel detector was specially designed for mobile use and the harsh conditions of industrial radiography and can be used with X-ray and gamma sources. The one-piece aluminum housing ensures maximum protection against external influences. It is also dust and waterproof and classified as IP67 according to IEC standard 60529. With its active area of 23.3 x 29.1 cm, excellent contrast and uniquely high resolution thanks to a pixel pitch of 76 µm, even the most demanding inspection tasks can be mastered. - Weld seam inspection - Pipe inspection, corrosion inspection, erosion inspection - Crack detection - Casting inspection

For high voltage energy supply/distribution Welding (incl. welding on bolts) Pressure testing with SF6 gas Full dimension check (providing DXF file) X-ray inspection of welding seams where possible, inspection of all other seams with ultrasound Mechanical engineering

The R-Series robots from Kawasaki can be used in a variety of applications and industries like welding, material removal, machine tending, inspection, dispensing and assembly. This high class technology has a total horizontal reach of 1,925mm and vertical reach of 3478mm. This cutting edge technology also boasts of its fast speed and the maximum speed of this is 13,100 mm/s.

The R-Series Robots from KAWASAKI ROBOTS can handle a maximum workload of 30 kilograms and speeds up to 13,400 mm/s. The 2.1-meter horizontal and 3.697-meter vertical reaches of the R-series makes it usable for assembling, inspecting, dispensing, welding, material handling and removing, machine tending, and other applications within a wide range of various industries. With these, the R-series from KAWASAKI sets the bar for small to medium duty industrial robots.