In the construction machinery sector, the boom is a critical load-bearing component for cranes, aerial work platforms, and other machinery. The precision and quality of boom welding directly affect the structural strength and service life of the entire machine. Traditional manual welding methods can no longer meet modern demands for welding efficiency, accuracy, and consistency, while automated “blind welding” is still hindered by part assembly deviations and other factors. With the advancement of intelligent manufacturing and industrial automation, leveraging advanced sensing and control technologies to achieve precise and automated boom welding has become a key challenge for the construction machinery manufacturing industry.
Laser Seam Tracking Sensor Overview
The Weld Navigator® Laser Seam Tracking Sensor is an intelligent sensing device based on high-precision laser measurement and image processing technology. It can scan weld seams in real time, generate precise 3D contour data, and transmit positional information to the robot control system to achieve dynamic torch guidance and path correction.
Key Features:
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High-Precision Detection: Millimeter-level positioning accuracy ensures stable and reliable seam tracking.
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Real-Time Response: High frame rate data acquisition and processing support high-speed welding operations.
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Strong Adaptability: Suitable for various weld types (fillet, butt, lap, etc.) and multiple materials.
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Strong Anti-Interference: Effectively resists arc light, spatter, and dust interference during welding.
Challenges in Construction Machinery Boom Welding
Construction machinery booms are typically made from high-strength steel plates and feature complex structures, long weld seams, and large welding volumes. Automated welding often faces the following challenges:
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Inconsistent Weld Positions: Large structural components may have weld position deviations from millimeters to centimeters due to machining and assembly tolerances.
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Long and Complex Welds: Boom welds often combine long straight lines with curved surfaces, making welding paths complex.
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High Production Cycle Requirements: In assembly line production, high efficiency must be achieved without compromising quality.
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High Dependence on Skilled Labor: Traditional welding relies heavily on experienced welders, leading to high labor costs and inconsistent quality.
Weld Navigator® Solution
To meet the specific requirements of boom welding, Weld Navigator® integrates its laser seam tracking sensor with FANUC robots to deliver an efficient and stable automated welding solution:
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Laser Positioning: Scans the weld start point before welding for precise positioning.
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Real-Time Tracking: Continuously detects the weld path during welding and corrects the robot’s trajectory in real time, avoiding misalignment or missed welds.
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Process Monitoring: Visualizes weld seam data and welding processes for quality traceability and process optimization.
Application Case
At a construction machinery manufacturer, the Weld Navigator® seam tracking sensor works in tandem with FANUC robots for automated boom welding on a production line. Weld bead consistency improved significantly, and the rework rate dropped sharply. Automatic positioning and dynamic tracking reduced manual setup time, boosting overall efficiency. The same line can also quickly switch between different boom models, enabling flexible automated welding and minimizing changeover time.
With extensive application experience and deep technical expertise in laser seam tracking, Weld Navigator® has addressed the adaptability challenges of traditional automated welding, helping the construction machinery manufacturing industry move toward intelligent and high-quality development. Looking ahead, Weld Navigator® will continue to enhance product performance, expand into more application scenarios, and provide manufacturers with smarter and more reliable welding solutions.
