Weld Navigator® Visual Molten Pool System CXZK-G6A

1. Product Overview

This product integrates both visual monitoring and welding camera functionalities, combining the features of two camera systems into one. It is capable of both molten pool monitoring and seam tracking. The product features are introduced in two parts below:

Molten Pool Monitoring:

During welding, to ensure consistent weld formation, operators must regularly observe the welding area, the melting point of the filler wire, and changes in the molten pool state in order to adjust welding parameters in real time. However, welding environments are harsh—operators are exposed to smoke, intense arc light, and spatter, requiring strict protective gear. Prolonged human monitoring under such conditions often leads to visual fatigue and inadequate supervision, negatively impacting productivity and the operator’s health.

The CXZK-G6A, developed independently by Chuangxiang Zhikong, is a visual molten pool inspection system capable of accurately capturing the position of the welding wire and the molten pool's state. It enables remote HD monitoring of the arc, filler wire (or tungsten electrode), molten pool, weld seam, base material, and detects issues like slag inclusion or bubbles. This real-time visual feedback allows for timely adjustment of welding parameters, improving both weld quality and production efficiency. The system solves challenges related to observation and monitoring in automatic welding environments, enhancing the reliability of welding systems. It is compatible with any automated welding equipment and significantly improves operator working conditions while saving labor and improving weld quality.

Visual Seam Tracking:

The system enables real-time seam detection and tracking during the welding process, ensuring weld quality and consistency. With high integration, strong anti-interference capability, and broad compatibility, it is an ideal choice for modern automated welding systems.

2. Structure and Working Principle

The CXZK-G6A Visual Molten Pool Detection Camera consists of a high-resolution sensor, high-performance processing chip, HD lens, and infrared light source. It is an advanced high-dynamic-range industrial vision sensor, capable of remote high-definition capture of the welding process through complex algorithms. The camera housing is made of aluminum alloy, offering a lightweight, fast heat dissipation, durable, and compact design.

3. Application Areas

• High-temperature molten pool monitoring for arc welding

• High-temperature molten pool monitoring for TIG welding

• High-temperature molten pool monitoring for MIG/MAG welding

• High-temperature molten pool monitoring for plasma welding

• High-temperature molten pool monitoring for laser welding

• High-temperature molten pool monitoring in furnaces

• 3D printing process monitoring

• Weld surface inspection

• General machine vision applications

• Supports standard Ethernet Modbus TCP communication protocol

• Compatible with various welding systems including linear seams, circumferential seams, welding carriages, gantries, and cross sliders

• Communicates with various robot brands to correct horizontal workpiece deviations

• Supports micron-level seam stitching and tracking for both linear and circular welds