The laser tracking system is intended for use as part of industrial robotic welding systems and is designed to automatically control the position of the welding head during the welding process, measure the geometric parameters of the weld groove, and provide the operator with the possibility of visual control of the welding process.
The system includes the following main and optional components:
·Laser Scanner ZLDS202Smart-Weld.
ZLDS202Smart-Weld differs from the basic configuration in the following
options:
- Built-in software packages for data exchange with robots and external industrial systems
- Special design that provides protection against aggressive influences during welding, namely, a special body, replaceable protective glass, pneumatic shutter, protective cover; window blowing system.
- Special equipment (taking into account the characteristics of the customer's system) for attaching the scanner to the welding robot. It is possible to equip the scanner with a pneumatic system for removing the scanner from the welding area.
- Predefined set of working ranges that provide a solution to welding tasks.
- Ready-to-use templates for the main types of welding grooves with the possibility to correct existing templates and add new ones.
· Rugged industrial tablet (optional) with pre-installed software designed to automatically search for a scanner on the network and open its web interface.
· Industrial Ethernet switch (optional).
· Scanner electrical protection unit (optional).
· Cables
direct connection of the scanner to the robot controller without an intermediate computing module;
control of the movement of the robot and full cycle of welding process;
built-in interfaces to popular robots;
ready-made file of various types of welding joints;
simple and intuitive building a work algorithm inside scanner WEB-interface using a graph of smart blocks;
3D real-time tracking visualization;
the set of scanners of various ranges, optimized for work in welding conditions.
7 models of:
compact, high-precision, high-speed scanners
available in Red, Blue diode wavelengths
| main parameter | | |
| Measuring ranges, mm: | from 25 to 250 | |
Linearity, % of F.S: | ±0.05 | |
| Measuring rate, profiles/s: | 484,938,4884,6379 | |
| Interface: | Ethernet / 1000 Mbps | |
| Synchronization inputs: | RS422, 3 channels | |
| Outputs: | RS422, 1 channel | |
Shock: | 30 g/6 ms | |
Enclosure rating: | IP67 | |
Power supply: | 9...30 V or 12...36 V for scanners with Blue laser |
The housing of the scanner is made of anodized aluminum. The front panel of the housing has two windows: the output window and the window for receiving radiation reflected from the object under control.
The scanner has one connector, Reset button and LED indicators. Pressing the Reset button for 5 seconds will restart the scanner. If you press the Reset button for 1 second, a broadcast Hello packet will be sent. Red LED indicates that the firmware is loading; green LED indicates that the Ethernet connection is established.
Laser scanners come with the following features by default: · additional protective quick-change glass for scanner windows; · a special fitting for supplying compressed air to protect the windows ("air knife" system); · a protective cover; · equipment for quick installation of the scanner.
Scanners can be supplied with the following laser wavelengths: · red laser scanners, 660 nm; · blue laser scanners (BLUE version), 450 nm.
Different lasers are used due to a wide range of applications. For example, the use of blue lasers instead of red ones is optimal for the control of shiny materials and high-temperature objects.
There are two operating modes in the full working range: Basic mode with the frequency of 484 Hz (profiles/second) and DS mode with the frequency of 921 Hz.
The ROI function has been implemented, which makes it possible to increase the working frequency of the scanner in the limited working range up to 4884 Hz in Basic mode and up to 6379 Hz in DS mode.
The laser tracking system is intended for use as part of industrial robotic welding systems and is designed to automatically control the position of the welding head during the welding process, measure the geometric parameters of the weld groove, and provide the operator with the possibility of visual control of the welding process.
| Range | MR, mm | SMR, mm | Хsmr, mm | Xemr, mm | Dimensions, figure | Weight, kg | Option: air or water cooling, drawing, figure | Option: shutter, figure |
| 25-65-20-22 | 25 | 65 | 20 | 22 | 1 | 0.7 | 2 | 3 |
| 50-75-30-41 | 50 | 75 | 30 | 41 | 1 | 0.7 | 2 | 3 |
| 100-70-48-82 | 100 | 70 | 48 | 82 | 1 | 0.7 | 2 | 3 |
| 130-70-40-86 | 130 | 70 | 40 | 86 | 4 | 0.7 | 4 | 4 |
| 130-250-52-76 | 130 | 250 | 52 | 76 | 5 | 0.9 | 5 | 5 |
| 200-82-60-150 | 200 | 82 | 60 | 150 | 1 | 0.7 | 2 | 3 |
| 250-90-65-180 | 250 | 90 | 65 | 180 | 1 | 0.7 | 2 | 3 |
| Sampling rate and accuracy | |
| Nominal sampling rate | 484 profiles/s (standard mode), |
| (full working range) | 938 profiles/s (DS mode) |
| Maximal sampling rate | 4884 profiles/s, |
| (ROI mode) | 6379 profiles/s (DS mode) |
| Linearity (measurement error), Z axis | ±0.05% of the range (standard mode), |
| ±0.1% of the range (DS mode) | |
| Linearity (measurement error), X axis | ±0.2% of the range |
| Resolution, Z axis | 0.01% of the range (standard mode), |
| 0.02% of the range (DS mode) | |
| Resolution, X axis | 648 or 1296 points (programmable value) |
| Laser | |
| 660 nm or 450 nm | |
| Class 2M according to IEC/EN 60825-1:2014 | |
| Interface | |
| Basic | Ethernet / 1000 Mbps |
| Synchronization inputs | RS422, 3 channels |
| Laser on/off hardware input | 1 |
| Outputs | RS422, 1 channel |
| Power supply | 9...30 V or 12...36 V for scanners with Blue laser |
| Power consumption, not more | 6 W (without a built-in heater) |
| Environment resistance | |
| Enclosure rating | IP67 |
| Vibration | 20 g / 10...1000 Hz, 6 hours for each of XYZ axes |
| Shock | 30 g/6 ms |
| Operating ambient temperature, °С | '-20…+40°С or -20…+80°С for scanners with built-in air cooling system |
-20...+150°С for scanners with built-in water cooling system | |
| Relative humidity | 5-95% (no condensation) |
| Storage temperature, °С | -20...+70 |
| Housing/windows material | aluminum/glass |
| Replaceable protective windows | glass |
· The laser scanner is mounted on the robot flange next to the welding torch in such a way that during the welding process and movement along the welding groove, the scanner is ahead of the welding tool.
· The scanner is calibrated to obtain the coordinate transformation matrix. The calibration procedure is described in the User's Manual for ZLDS202Smart.
· Using the web interface of the scanner, a computation graph is formed from the library of smart blocks (examples are given in User's Manual), taking into account the specifics of the equipment, namely the robot type, communication protocol, groove type, geometric parameters of groove templates used to control the position and constraints applied to them, etc. If the supplied file does not contain the required groove template, the user can create a new template himself or with the support of the manufacturer using the provided template editor (see User's Manual for ZLDS202Smart).
· The script for controlling the groove tracking block and the welding robot is being configured (examples of scripts are given in this User's Manual). The control script provides cyclic execution of the main stages of welding: placing the welding tool in the starting position, moving the tool in the direction of the beginning of the groove (search for the entry point into the groove), bringing the tool to the beginning of the groove and generating signals to external systems (welding controller) about the need for ignition and other actions,stopping the robot movement, transferring the coordinates to the robot for the movement of the tool along the welding groove, bringing the tool to the end of the groove and generating signals to external systems (welding controller) about the need to reduce the current or extinguish the arc (and other actions),bringing the tool to its original position.
· During operation, each profile received by the scanner is processed in accordance with the algorithm specified by the graph, and the following steps are performed: detecting the welding groove template in order to determine the exact coordinates in the scanner coordinate system (2D), transforming the coordinates from the scanner coordinate system to the robot coordinate system (3D), forming the trajectory of the tool in the robot coordinate system, transferring the coordinates to the robot for movement to the next position of the trajectory.
Operation of the scanners is based on the principle of optical triangulation:
Radiation of a semiconductor laser is formed by a lens in a line and projected to an object. Radiation scattered from the object is collected by the lens and directed to a two-dimensional CMOS image sensor. The image of object outline thus formed is analyzed by a signal processor, which calculates the distance to the object (Z-coordinate) for each point of the set along the laser line on the object (X-coordinate). Scanners are characterized by base distance (beginning of the range), SMR, for Z-coordinate, measuring range (MR) for Z-coordinate, measuring range for X-coordinate at the beginning of Z (Xsmr) and measuring range for X-coordinate at the end of Z (Xemr).
The laser tracking system is intended for use as part of industrial robotic welding systems and is designed to automatically control the position of the welding head during the welding process, measure the geometric parameters of the weld groove, and provide the operator with the possibility of visual control of the welding process.
The laser tracking system is intended for use as part of industrial robotic welding systems and is designed to automatically control the position of the welding head during the welding process, measure the geometric parameters of the weld groove, and provide the operator with the possibility of visual control of the welding process.
Fig.1 |
|
| Fig.2 |
|
| Fig.3 |
|
| Fig.4 |
|
| Fig.5 |
|
ZLDS210 2D Laser Profile Scanner
ZLDS10X High-precision laser triangulation sensor
ZLDS11X High Temperature Laser Displacement Sensor
