VIRO WSI automated weld-seam inspection

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VITRONIC VIRO WSI inspects weld seams on an axle carrier for a Tier-1 supplier. (PHOTO courtesy VITRONIC Machine Vision)

Leading the evolution in the new generation of automated inspection of weld seams is the VIRO WSI Weld Seam Inspection System, designed and manufactured by VITRONIC Machine Vision – a provider of specialized products and software for image-based quality inspection, identification and process optimization.

Integrated Inline Inspection, Expanded Inspection Range and Simplified Reworking were introduced by the VIRO WSI Weld-Seam Inspection System, and constitute integral functionality of its operation. These systems are successfully being used by leading automotive OEMs and Tier-1 suppliers.

The optical inspection system is a fully-automated solution that inspects all weld seams and detects defects as small as 0.1 millimeter, visualizing these for reworking. VIRO WSI uses laser triangulation. This allows laser seams and fine brazed seams to be inspected quickly and with high resolution in 3D. The sensors were specially developed for inspections on reflective materials like aluminum.

As well as being objective and independent of external influences, VIRO WSI consistently follows predefined quality criteria.

Seamless Documentation and Analysis

In the VIRO WSI system, all weld-seam inspections are seamlessly documented, stored in an integrated database, and are fully traceable during the entire production process. From this data, operators can quickly identify any potential for production optimization, and immediately determine any action that may be required. Completed rework and evaluations of inspection results are then manually entered into the database.

The parameters for quality inspection can then be adjusted during the production process and automatically applied to the next system cycle. This minimizes costly reworking and scrapping of parts.

The database enables operators to initiate effective long-term optimizations and implement these on an ongoing basis. This ensures more efficient processes, reduces costs, and continually enhances the quality of the automotive component manufacturing.

Integrating Weld Data with Process Data Supports Process Optimization

Inspection data may enable operators to identify weld-seam errors, but it does not reveal what caused them. Supporting this new generation of weld-seam inspection is WeldLoop software, also from VITRONIC, which links data from VIRO WSI weld-seam inspection with a welding system’s process data. This allows large data volumes to be efficiently analyzed and trends recorded graphically.

The software enables visual representation of the connections between optical image data, measured inspection data, and process data. For example, a graphical representation of the relationship between the measured values for weld volume and plate gap in the form of a scatter plot. By comparing the seams, deviations can be detected very quickly, and possible sources of errors can be pinpointed.

By performing trend analyses and visualizations, technicians can quickly detect deviations and their possible causes, as well as the welding station where they occurred. This enables action to be taken immediately to eliminate error sources, and it optimizes the accuracy of the inspection itself.

The additional data obtained from WeldLoop can be used to optimize the welding process much faster and in a more targeted way to prevent future defects. As a result, manufacturers can significantly cut costs, reduce downtime, and avoid waste.

For more information contact VITRONIC Machine Vision Ltd. USA,

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