8698 Elk Grove Blvd. Ste , Elk Grove, CA, Tel / Cell

Transcription

1 8698 Elk Grove Blvd. Ste , Elk Grove, CA, Tel / Cell Web site: simonlaser@yahoo.com Page 1 of 8

2 Results of the measurements - sample Each weld plume is recorded and saved as a JPG image. Evaluation of each image is presented with the plume image. Please note that Pulse No 9 failed since the value of the evaluation was only 65.03%. The PASS criteria was set at 90% Statistical data of each welded assembly PLUS the statistical data of all laser welded assemblies in a given lot are also summarized. Serial No 3 failed because of the low Min value. Serial No 4 failed because there were too many pulses fired at the material. This illustration is the enhanced copy of the actual.xls file. Page 2 of 8

3 Product description (US Patent Applied for) This CMOS smart-camera based laser weld monitoring system monitors the key characteristics of the laser welding process. It is designed primarily to work with pulsed laser power as generated by commercially available industrial Nd:YAG, solid state and fiber lasers. These lasers typically generate output wavelengths at approx. 1.0 microns. When the spatial and or the temporal characteristics of the welding process change and the changes exceed the upper or the lower limits as set by the end user, alarm messages are generated. The captured image of each weld plume is analyzed statistically and the data (of each weld) is saved to file. The HDEm System is a fully integrated weld monitoring system in a package approx. 6 x3 x1. Weight of the camera is only 14 oz. Additional components add to this weight. The camera is supplied and guaranteed by a multi-hundred million dollar company. All optics and mechanical components are designed and fabricated by quality suppliers. The HDEm System is self triggering, hence: It is not connected to the controller of the laser power supply. No interface needed. It is not connected to the controller of the workstation. No interface needed. The data generated and analyzed by the HDEm System is automatically downloaded to the customer s computer via an Ethernet cable. The HDEm System does not interfere with the current laser beam delivery system. Hence re-qualification of the current welding process and the laser welded products may not be necessary! Tack welds can be programmed as part of the weld sequence. Image processing time is approx. 14 microseconds. Images are analyzed for shape, size intensity and location. Pulse width of the laser may be from 0.1 msec to 20.0 msec. Pulse rate capability: Single (one) pulse to 25 pulses per second. In some configurations, the HDEm System may be used like a normal CCTV camera as well as a Pulsed Weld Monitor. HDEm System is supplied with very complete instructions for installation, calibration and operation both hard copy and electronic format. Training is included in the quoted costs. Installation is often done by the end users! Professional technical support is available for installation and service. Additional details are available in the Technical Specifications supplied upon request. Page 3 of 8

4 Configurations The selection of the configuration to be used is based on the following information: 1. Configuration of the current electronic target viewing system (CCTV). 2. The laser weld process parameters. Configuration 1. When the current CCTV system is simply a target viewing device, the HDEm System camera replaces the current CCTV and may be used both as a target viewing device and as a Pulsed Weld Monitor. Energy per pulse should be below 1.0 joule. Some of the components that are supplied with this configuration are not shown on this photo. Page 4 of 8

5 Configuration 2. This is the configuration that is recommended when the current CCTV system is a target viewing device and is also connected to a some image tracking system that performs seam tracking and computation of the contour of the weld path. In this case the HDEm System camera is installed as an additional device, taking approx. 20% of the target image during welding to perform the weld monitoring functions. The HDEm system in this configuration does not interfere with the current image acquisition and image processing system. Energy per pulse may be up to 25 joules. Some of the components that are supplied with this configuration are not shown on this photo. Page 5 of 8

6 Weld monitoring performance The HDEm System has been tested and found to be able to identify changes the following weld process variables: 1. Weld geometry 1.1 Gaps in the weld joint aligned with the weld: < Gaps in the weld joint transverse to the weld: << Butt weld joint misaligned parts: < Lap weld joint gaps between the pieces: t.b.d. 2. Any mechanical interference with the weld (clamps, fixtures, etc.) 3. Too many or too few pulses fired in to the material. 4. Pulses that did not produce good quality welds. 5. Shield gas changes in the type, volume and the direction of gas flow. 6. Changes in the focal position of the final focus lens. 7. Changes in laser power. (Hint: since the image processing time is approx. 14 micro seconds, the response of the HDEm System to laser power changes is significantly faster than the response time of most power meters!) 8. Etc. Pre-installation requirements (customer supplied). It will be assumed that the currently installed laser beam delivery optics on the customer s laser welding system will have following features: 1. CCTV camera with C5 mounting thread and all the adapters and optics that are installed in the beam delivery optics (BDO) to produce an image on the monitor of the CCTV. 2. Attenuation optics in the BDO that control the light intensity now entering the CCTV camera VAC 5 Amps power outlet near the BDO. 4. A computer with the Windows Operating System XP or Windows Prior to the sale and installation of the HDEm System the following information about the laser beam and the process characteristics should be measured and supplied to HDE for evaluation. 5.1 Photo of the current laser beam delivery system. 5.2 Spatial profile of the laser beam at the focus. 5.3 Temporal profile of the pulses. 5.4 Laser welding parameters. Page 6 of 8

7 Cost: Exact costs will be quoted after the client requirements and the details of the current (or future) laser beam delivery system are evaluated. Approx. $15, per system. (Typical Configurations 1 and 2) Approx. $17, per system. (Typical Configurations 3 and 4) Delivery : days ARO. (typical) Additional services offered by HDE will be quoted separately when so requested. 1. Assist the customer to perform laser beam metrology measurements. The results of these measurements are critical to the configuration and the installation of the HDEm Pulsed Laser Weld monitoring system. The customer bears the costs of the time and the equipment that may be needed to make these measurements and to collect the data. 2. Computation of the optimum pulsed laser weld parameters using the HDE Pulsed Laser Weld computational algorithm. (NO charge). 3. Training. In addition to the on-site hands-on training provided as part of the sale of the HDEm System, HDE offers to Register one (1) technical person from the client company to one of HDE s Laser Welding Technology courses. (NO charge). 4. Installation. The HDEm System was designed to be installed by the customer with some assistance by HDE at NO charge. However, if the customer wishes HDE to perform the installation(s), then HDE will provide trained technicians and or engineers to do the work. Ask for a quote. 5. On-site, hands-on training of technicians and operators to perform their own future installations, beyond the normal installation. Ask for a quote. 6. Software package to allow the networking of several HDEm Systems as may be needed in welding operations where simultaneous welds are made. Ask for a quote. 7. High speed version of the HDEm Systems (up to 120 pps pulse rate). Cost to be quoted Page 7 of 8

8 Disclaimers. The HDEm Pulsed Laser Weld Monitor is a system that is able to identify changes and variations in the laser welding process in real time, analyze the data and report it to the end user. The accuracy of the reporting is subject to a number of process related variables and their interactions with each other and the process limits set by the end user. Although it is tempting, the end user is advised to NOT use the HDEm System as a device to determine the final quality of the welded product. HDE recommends that the end user continues the normal inspection and testing of the laser welded product as the end user has been doing in the past and as it was approved by the Industry Specific Regulatory Agency. HDE is not accepting any responsibility as to the accuracy of the HDEm System and the final quality of the laser processed components Page 8 of 8