Robotic 3D Scanner Welding with On-the-fly Seam Tracking Robotergestütztes 3D-Scannerschweißen mit On-the-Fly Nahtverfolgung

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1 Robotic 3D Scanner Welding with On-the-fly Seam Tracking Robotergestütztes 3D-Scannerschweißen mit On-the-Fly Nahtverfolgung Dr.-Ing. Wolfgang Vogl Dr.-Ing. Ulrich Munzert Dr. Uwe Megerle Blackbird Robotersysteme GmbH Blackbird Robotersysteme GmbH Scanlab AG Bad Nauheim, February 12 th, 2014 EALA European Automotive Laser Applications 2014 Blackbird 2014 Datum: Page 1

2 Agenda Introduction State of the art Approach and implemented system Application example at BMW Summary Blackbird 2014 Datum: Page 2

3 Introduction Company Blackbird Robotersysteme GmbH Part of Scanlab Group Located near Munich, Germany Robotic software and control solutions Focus: Integrated solutions for robotic scanner welding Products: Software, controls and computer vision Service: Training, installation, engineering Blackbird 2014 Datum: Page 3

4 Introduction Scanner Welding Solutions System Components Options RobotSyncUnit Scanner Controller IntelliWELD 3D Scanhead ScannerVisionSystem 2D Seam Finding RobotMotionCenter Offline Programming Accessories: Crossjet Teaching Aide Vision ports, etc. Integration with 3rd party sensors for process monitoring for position sensing Interfaces and compatibility: Industrial I/O and Safety (Devicenet, Profinet, ProfiSafe, etc.) Robots / Handling Devices (KUKA, FANUC, ABB, MOTOMAN, Gantry, etc.) Fiber-coupled Lasers up to 8 kw (IPG, ROFIN, TRUMPF, etc.) Blackbird 2014 Datum: Page 4

5 Integrated Contoller 3D Synchr. Robot / Scanner State of the art Robot-based scanner welding Laser Scanning Head 2 or 3 DOF Small working volume High accuracy High repositioning speed (ms) Extensive fine control of motion small radii, sharp edges velocity, power, defocus, oscillation On-axis observation possible Minimimized repositioning times Omnidirectional Processing Articulated Robot Arm 6 DOF, i.e. access from all sides Large working volume Medium accuracy Medium speed Flexible automation tool Overall accuracy limited by: robot axes + parts tolerances + tooling Blackbird 2014 Datum: Page 5

6 State of the art Videoclip pre-programmed 3D on-the-fly processing Blackbird 2014 Datum: Page 6

7 Task description Remote laser welding of fillet joints Overlap Joint Typical for On-the-Fly Remote Welding Fillet Joint On-the-Fly Processing Hitherto Impossible - Larger flanges required - Requires controlled gap for gas release if steel is galvanized (=> dimpling) - Only indirect quality assessment - Higher laser powers required - Lower accuracy is tolerable - Smaller flanges enabled - No additional measures required to release zinc gas - Geometric quality evaluation possible - Less laser power required - High accuracy required (~0,1mm) Blackbird 2014 Datum: Page 7

8 State of the art System approaches for seam tracking State of the art Proposed System Feed / Jump Robot Robot Robot Robot + Scan-axes Correction Robot Robot Scan-axes Scan-axes Sensor Probe (Wire) Laser triang. Laser triang. Coaxial Camera + lllumin. Weld direction Defined By wireprobe Perpendicular to laserline Perpendicular to laserline Omnidirectional Scanner Scanner Fixed Optic Fixed Optic Blackbird 2014 Datum: Page 8

9 Approach Scanner with dynamic seam tracking Robot-guided 3D Scanhead Camera Illumination High speed camera by Lessmueller, On-axis illumination and observation Automated focussing of camera along z-axis through scanhead Edge resolution ~ 0.1 mm Dynamic correction of welding position at 100+ Hz Control integration for full robotic 3D On-the-Fly Welding Precise welding of fillet joints Omnidirectional 3D-Processing Large stand-off and work volume Highest efficiency => Full 3D-On-the-fly Welding with Tracking! Blackbird 2014 Datum: Page 9

10 Implemented system Scanhead with coaxial camera and illumination Camera Up to 8 kw, 100µm fibers Post-Objective Scanhead f=660 mm with Internal lens, Magnification 6.0:1 (e.g. 600µm spot with 100µm fiber) d w =472 mm Illumination Excellent aptitude for computer vision Large working volume Example of square shaped work envelope (unit: mm) Blackbird 2014 Datum: Page 10

11 Implemented system Setup and components Front Side Opel / TKSE Datum: Page 11

12 Implemented system Programming and setup Integrated Programming w. RobotSyncUnit, method similar to standard scanner tasks: 1. Define global robot path (online or offline) 2. For each weld, define: Seam positions Laser parameters Seam finding parameters 3. Optimize reachability and timing 4. Optimize seam finding strong guidance through assistance functions and preview / simulation Blackbird 2014 Datum: Page 12

13 Implemented System Video Lessmüller Weldeye camera and RobotSyncUnit controller ensure robust seam tracking. Furthermore, excellent analysis tools are given to the user for setup and inspection Blackbird 2014 Datum: Page 13

14 Integrated Solution Robotic Scanner System with Seam Tracking IntelliWELD 3D Scanhead Lessmüller Weldeye Camera system RobotSyncUnit Integrated Controller Interfaces: PLC/RC (Master) Laser Source Inspection System Dynamic correction Safety Circut User I/O Seam tracking function fully integrated with software and controls One integrated solution package delivered Efficient installation and ramp-up Blackbird 2014 Datum: Page 14

15 Application example Car doors with fillet seams Door Welding for BMW / Mini Multiple systems implemented in serial production Image by courtesy of BMW Group Image by courtesy of Bergmann & Steffen GmbH Blackbird 2014 Datum: Page 15

16 Summary Novel technology has been developed that combines: Efficiency and flexibility of on-the-fly welding and precise seam tracking => unprecented speed and accuracy Industrial qualification for fillet seam door application with BMW Multiple systems implemented in serial production System requires controlled conditions (part design, edge tolerances, tooling) Initial target scope: Fillet joints in overlap configuration High volume applications at OEM and Tier1 Blackbird 2014 Datum: Page 16

17 Like to evaluate your application? Blackbird 2014 Datum: Page 17

18 Thank you very much for your kind attention!

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