Seam Guided Laser Remote Welding with Automated Gap Bridging Increased process windows by online recognition of gap situation

Due to high productivity and potential for cycle time reduction, Laser Remote Welding is gaining more and more attention particularly in automotive manufacturing and its tiered supply base. In a typical industrial setup, component tolerances are a major challenge to the usage of laser remote technology. The difference between programmed beam position and the actual component location can only be compensated by complex and thus costly design measures. In addition, a changing gap situation makes it difficult to choose suitable process parameters to reach a bridged weld seam. The presented approach for a laser remote welding system not only detects the correct component location, but furthermore measures the actual gap real time during the process and adapts process parameters according to a process model. The focus will be for fillet type welds of aluminum and steel alloys and their model based parameters.