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Here you will find several of our reference customers plus examples, which prove how the users have experienced the usefulness of PROMETEC Monitoring and Optimization Systems:

  • Weld Monitoring
  • Beam Diagnostics

Welding Monitor PD 2000
Spatial (two-dimensional) camera-based laser process monitoring
Plasma Monitor PM 7000
one-dimensional photo detector based laser process monitoring

Comprehensive quality assessment and tighter warranty terms for industrial goods plus the associated quality measures neccessitate In-Process monitoring systems. Scrap parts should be detected immediately and without much effort, their occurrence has to be documented.

Example for camera-based process monitoring for Remote Welding

Remote Welding is common laser weld process in the automotive industry. It makes the same demands on quality assurance as any other laser weld process. This integration of Welding Monitor PD 2000 developed by PROMETEC into TruLaser Scan 5024 by TRUMPF proves, that an established process monitoring system can be used for remote welding with the same positive results as in other laser processes in sheet metal working.

This image shows the placement of PD 2000's camera directly below the laser (also note the diagram further below).

Remote Welding

Remote welding or scanner welding is a laser welding process which has becoe common within the automotive industry and its suppliers. The workpiece is fixed, while the focussed laser beam is guided over the welding area by tilting of a highly dynamic mirror. Tiny movements of the mirror mean large deflection of the beam, thus the beam can be positioned very quickly. Non-productive downtimes for positioning of the laser optics are practically not required any more. That is the reason that remote welding is not only used with small parts but more and more in sheet metal working in the automotive sector. The advantage becomes evident especially when lots of welds have to be produced on different parts of the workpiece.

Systems for remote welding can be purchased from differnet manufactures. All differ in their adaptability for quality-assuring process monitoring systems. The TRUMPF scanner system TruLaser Scan 5024 (before 2007 available under its old brand name TrumaScan L 4000) is equipped with reflecting optics. A small pinhole in the focussing mirror for the process monitoring system allows for a coaxial insight into the manufacturing process.
The camera-based process monitoring solution uses an image of the process zone on the sensor surface of the camera. The PROMETEC Welding Monitor PD 2000 did prove its usefulness on many different laser manufacturing processes already. The special challenge in this case results from the large working area of the TruLaser Scan 5024. Its size is approximately 1.5 meters by 3.9 meters which results in a traverse path of the focussing mirror of 2.4 meters!

Integration PD2000 beim remote Welding

For integration of PD 2000 its camera is fixed within the machine housing. The axis of the camera’s optic is aligned with the pinhole in the focussing mirror. A second optic is applied directly behind the focussing mirror. This optic makes sure, that the camera image retains its size independently from the position of the focussing mirror. This ensures that the proportions of the camera image always remain the same, even when the distance between mirror and camera changes. Both optics do not need any active elements for adjustment according to the current position of the mirror.
This ensures a coaxial sight of the camera into the process zone. The PD 2000 software generates signals from the high-frequency camera images taken from the weld process. These signals are monitored by flexible limits, which generate alarms for the machine control, as soon as the process leaves its predefined parameters. This monitoring principle does not depend on the beam source and is applied on all established laser processes like welding, cutting, and coating.
Apart from the signals, the user can also use the images themselves. They can be saved as movies and thus being watched in animated form. Their intuitive comprehensibility allows for new insights into the process, which often leads to process optimization.


Just one example among others ... do you want to know more?

For a number of years now PROMETEC have been setting the standards in the inspection of laser beam sources and systems. PROMETEC systems are now widespread not only in laser research centers and laser manufacturers, but also in industrial facilities for laser materials processing, for welding, cutting or surface finishing.

Quality assurance through beam diagnostics

Diagnostics of focussed and unfocussed high-power laser beams

Detection of adjustment errors and damage to the laser and beam guides

Process reliability by system and process optimization

Minimization of scrap, quality improvements