Visi­on-Gui­ded Laser Welding

InvotecCase Study, Machine Vision Systems, Micro Laser Processing, Precision Joining

Laserschweißgerät einer Medizingeräte-Montageanlage

Visi­on gui­d­ance is used in situa­tions whe­re the com­bi­na­ti­on of tole­ran­ce stack-ups, beam dia­me­ter, and fea­ture size would cau­se incon­sis­tent welds.

The Chal­len­ge With Pre­cisi­on Laser Welding

When you manu­fac­tu­re medi­cal devices, auto­mo­ti­ve sen­sors, and other intri­ca­te pro­ducts, fail­u­re is not an opti­on. With tight tole­ran­ces and com­pli­ca­ted assem­bly pro­ces­ses, con­sist­ent­ly laser wel­ding com­plex com­pon­ents can be a dif­fi­cult task to accom­plish and main­tain over a long peri­od of time in a pro­duc­tion environment.

The focu­sed spot dia­me­ter for laser wel­ding app­li­ca­ti­ons is typi­cal­ly 100–1,000 microns. The posi­ti­on of the joint under the laser must be pre­cise enough to ensu­re that the focu­sed spot does not miss.

The allo­wa­ble misa­lign­ment is a func­tion of the focu­sed beam dia­me­ter as well as the joint design and is typi­cal­ly in the ran­ge of ±75 microns.

For many app­li­ca­ti­ons, hard too­ling is suf­fi­ci­ent to loca­te the part for wel­ding. Howe­ver, in app­li­ca­ti­ons whe­re part tole­ran­ces exceed ±75 microns, acti­ve posi­tio­ning of the weld joint and/or laser spot are requi­red for an accu­ra­te, con­sis­tent weld.

Brin­ging Visi­on Gui­d­ance to Laser Welding

Invo­tec Engi­nee­ring has inte­gra­ted visi­on-gui­ded laser wel­ding sys­tems into a wide ran­ge of cus­tom equipment—including laser spot wel­ders, seam wel­ders, and laser machi­ning centers—to sol­ve com­plex wel­ding pro­blems for the medi­cal device, auto­mo­ti­ve, and defen­se industries.

Here’s how it works:

A visi­on inspec­tion sys­tem is used to deter­mi­ne whe­re the focal point of the laser ener­gy will land rela­ti­ve to the fea­tures to be welded.

Once the off­sets are deter­mi­ned, a ser­vo posi­tio­ning sys­tem moves eit­her the ter­mi­nal optics or the parts to be wel­ded, ensu­ring the ener­gy is deli­ve­r­ed to the cor­rect weld location.

The­se pho­tos demons­tra­te the accu­ra­cy of a visi­on-gui­ded laser weld as oppo­sed to a tra­di­tio­nal weld. In the first pho­to, the magen­ta line is the posi­ti­on of the weld seam. The yel­low line is whe­re a tra­di­tio­nal laser wel­ding sys­tem will place the weld seam. This would pro­du­ce a rejec­ted part.


In the second pho­to, the sys­tem auto­ma­ti­cal­ly aligns the laser path with the weld seam. The red wel­ding tar­get is now pro­per­ly pla­ced on the seam. The result is an appro­ved part each time.


By incor­po­ra­ting visi­on-gui­ded laser wel­ding sys­tems, our cus­to­mers auto­ma­te pre­vious­ly manu­al weld operations—improving weld qua­li­ty and con­sis­ten­cy, redu­cing scrap, and incre­a­sing throughput.

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