As the rail transit industry continues to develop, train body manufacturing is also steadily moving toward greater intelligence. Welding, being a core process that directly affects the structural safety and performance of train bodies, is now subject to higher demands for precision and automation. Especially in the welding of structurally complex components, traditional manual welding struggles with inefficiency and inconsistency, failing to meet modern standards. To address this, the Weld Navigator® laser seam tracking system has been deeply integrated with FANUC industrial robots to provide an efficient and precise intelligent welding solution for train end walls.
Technical Challenges in Automatic Welding of Train End Walls
Train end walls are critical structural components that connect key parts of the vehicle. They are typically characterized by long weld seams, narrow welding spaces, and strict geometric tolerances. In traditional welding, manual teaching or offline programming is required—processes that are not only time-consuming and imprecise but also vulnerable to issues caused by assembly deviations and thermal deformation. These factors often result in weld seam misalignment or defects, which could compromise the structural integrity of the entire vehicle. Thus, fast seam recognition, real-time tracking, and automatic correction have become essential for achieving intelligent welding upgrades of end walls.
Working Principle of the Laser Seam Tracking System
The Weld Navigator® laser seam tracking system uses a line laser scanning principle. It employs a high-precision laser sensor to perform non-contact scanning of the weld seam, capturing real-time data on its position, shape, and deviation. In end wall welding, two core functions of the tracking system are utilized:
-
Laser Seam Finding: Before welding begins, a pre-scan identifies the starting point and overall contour of the seam. The system corrects seam deviations and generates a precise welding path—eliminating the need for repetitive manual teaching.
-
Real-Time Tracking: During welding, the system dynamically monitors seam deviations and adjusts the welding torch’s trajectory accordingly, enabling automatic compensation and precision welding.
With Weld Navigator®'s high-speed data processing and advanced control algorithms, the welding torch is consistently maintained at the seam center, enhancing weld accuracy and consistency.
Weld Navigator® Solution
The Weld Navigator® system, when integrated with a FANUC robot, forms a complete intelligent welding workstation. Once deployed, the robot can automatically generate welding paths based on laser seam finding data—no manual teaching required. During welding, real-time tracking ensures full intelligent control of torch positioning in response to seam deviations. Key advantages of this system include:
-
No Repetitive Teaching: Seam deviations are automatically corrected without manual intervention.
-
High Adaptability: Handles complex geometries and assembly errors with precise trajectory adjustments.
-
Consistent Quality: Ensures uniform weld quality and significantly reduces defect rates.
-
Easy Integration: Compatible with various robot brands and easily deployed on different production lines.
Application Case
The Weld Navigator® laser seam tracking system has been successfully implemented for batch welding of train end walls. In actual production environments, the system runs stably, automatically completing seam detection, path planning, and weld tracking. It effectively solves issues such as difficult manual teaching, frequent seam misalignment, and low weld accuracy. After implementation, the project has seen a significant boost in production efficiency, enhanced product consistency, and improved structural reliability—earning high praise from customers.
Weld Navigator® remains committed to welding automation innovation. By leveraging laser vision seam tracking and intelligent control technologies, we empower industries such as rail transit, construction machinery, and heavy manufacturing to improve quality and reduce costs. We will continue to deepen our efforts in intelligent welding and support more industries in achieving high-quality automated upgrades.
