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Welding inspection systems

FOR STRIP AND THIN PLATES

Wise (acronym of Welding Inspection System Embedded) is a welding inspection device which can be embedded into an existing automatic welder and it provides the overall quality of the welding, just after the welding process. Line operators can automatically check-out and validate the welding process immediately after it has been done, with the great advantage to avoid breakages on the following processes. The key feature of the welding inspection performed by Wise is that the scan is made at the same time of the welding process, that's why no extra time for line stops will be added to the normal time used for the welding.

WISE is unique
Wise is a unique system in industry: no other systems can do the same. Existing systems for the welding inspection based on different technologies, like PEC (Pulsed Eddy Current), magnetic, or visual may only identify a surface defect, but not an inner and not visible defect. WISE is innovative and will add a lot of possibilities to your standard way of work. The system has been developed to be easily incorporated on a large variety of existing automatic coil joiners, to provide a validity check of the welding directly after the welding process. Due to the reduced dimensions and realtively low weight, it will be an unparalled solution to minimize risks due to non conformity weldings and anomalies of the welding process. Wise is an X-ray tehcnology based analyzer specifically designed to recognize welding defects on cold metals strip and it is based on a latest generation micro-focus X-ray source combined to an high speed Time-Delay-Integration (TDI) camera as detection. Wise will provide a real-time analysis of the welding, directly during the strip forming process.

How WISE is different from other systems
Wise key feature is that can identify, with a very hig reliability, a lack of welding material: no otherexisting systems can do that. Systems based on different technolgies like PEC (pulsed eddy current), magnetic, or visual could only identify a surface defect, but not an inner defect.

Weak weldings and bead evaluation
A weak welding is a potential source of troubles for the process, not only for the quality of the final product, but mainly for the process itself. Strip breakages, for example, are a big issue for operator's safety and the 75% of strip breakages, on pickling lines, are caused by a weak welding. Defects in welding process are very small and require a magnification to enlarge the vision for data analysis, using a standard X-Ray source the contours of elements appear blur and the recognition is quite difficult. Using a microfocus technology with a very small spot size, it is possible to obtain the best image resolution and defects magnification, in order to identify unconformities.

  • BEAD HEIGHT
  • BEAD WIDTH
  • BEAD RATIO
  • MISMATCH
  • DEFECT
  • HOLE DETECTION

Additionally to the welding bead measurements the system provides the overall quality and hole detection near the welding bead (e.g. Malformed edge, hole in the strip, occlusions).

At today, no other systems in the market can offer the same features of WISE.

Data Analisys The real-time images captured from TDI camera are submitted to a high-performances data analysis processor that uses image processing and shape recognition algorithms to measure the bead of the weld and the presence of defect. Finally, the results are showed to operator that can immediately check if the welding system is working properly. All measures can be delivered to the plant automation using analog output, hardwired digital output and/or via digital protocols. For best accuracy the system can receive line setup from Plant automation/PLC/upper levels (line speed, material thickness, etc) through protocol or manually by operator's HMI. The system can works also in full automatic mode without any settings, in this case the accuracy of recognized shape of hole / defect can be lower. The analysis of the welding can be performed when the welder is going forward (during welding process) or backward (when the welder goes to home position). Backward scan mode is preferred for thick material where an accurate analysis require a lower scanning speed.

About WISE development

WISE is in constant development! We are daily improving its capabilities. Since we have received numerous expressions of interest in our online welding inspection system over the past year. WISE is a system born from the request of one of our long-standing customers. The possibilities of the WISE system are many more than those currently implemented, and therefore WISE is in continuous development on our part. If you are a production line owner and would like to have control of WISE on your line, contact us! We need to test our system on as many lines as possible, and we could find a formula to install the system at no cost with you.