Sensor Technology
| BOOTH 28 E100.MB5 | S&F System Technology - Commissionings and Laser Machines The enterprise S&F Systemtechnik GmbH is a spin-off from the Fraunhofer ILT, being founded in 2001. Programming of system kernels is the key competence. As a result of rising requirements of our industrial customers we now perform tasks in the domain of modernizing (Retrofit) and developing solutions for IPC, NC and PLC based automation systems. Furthermore, we offer components and complete machines for laser materials processing. Productivity, usability and flexibility come to the fore. The enterprise introduces at AKL'10 its business areas "Commissioning", "Retrofit" and "Machines for innovative laser processing". Examples, references and work samples of several carried out projects are presented. It is planned to show the following exhibits:
Contact Person Dipl.-Ing. Lars Böske Phone +49 241 8906-427 boeske@sf-systemtechnik.de SF Systemtechnik GmbH | |
| BOOTH 19 E100.ROB | Demonstration of Active Laser Safety System Laser-Spy for Brilliant High Power Laser Sources This experiment is designed to point out the inherent safety risks for machinery and operators when using brilliant high power laser sources and the solution to minimise these risks. The active Laser-Spy sensor monitors the inside of a light tight double walled housing element and shuts down laser operation upon intrusion of radiation into this housing element prior to breach of the outer wall. The demonstration set-up includes an additional sensor system to measure the time it takes the laser to penetrate the inner wall in comparison to the actual Laser-Spy reaction time. Contact Person Günter Neumann / Dr. Frank Schneider Phone +49 241 8906-426 frank.schneider@ilt.fraunhofer.de Fraunhofer Institute for Laser Technology ILT | |
| BOOTH 08 E100.CPC | Laserbrazing The setup of coaxially integrated quality control system for laser brazing is exposed. Two cameras are observing the process in different spectral regions. The first camera collects the reflected light of an external illumination while a second camera records the near-infrared spectral region. Hence, a real image and a distribution of the thermal radiation are generated. With the combined analysis of these two images it is possible to measure process parameters like brazing velocity, brazing time and process geometry. Moreover seam imperfections like pores, surface quality and the wetting behaviour of the joint can be detected while their emergence. As an additional time and money consuming off-line inspections is avoided by this system it is a useful application for industry where demands on seam quality are very high, e. g. in the automotive sector. The presented system provides the opportunity to control the quality of the seam during the brazing process. Results and film material of a brazing process are shown in a presentation. Contact Person Dipl.-Phys. Michael Ungers Phone +49 241 8906-281 michael.ungers@ilt.fraunhofer.de Fraunhofer Institute for Laser Technology ILT | |
| BOOTH 09 E100.CPC | Measurement of the Powder Density Distribution for Powder Feed Nozzles The Laser Metal Deposition has established as a technology for functionalization of surfaces, repair and modification of components as well as generation of new parts. The most important field of application is the manufacturing of tools and combustion engines, stationary gas turbines and aero engines. At the laser cladding process a filler material in form of a powder is melted using the laser beam and fused with the base material. Therefore the powder feeding into the melt pool is an important influencing variable for the result of the process. The powder efficiency, the oxidation by the ambient atmosphere and the roughness of the cladded layer are influenced by this parameter. For this reason there is a need for a characterization of the powder-gas-flow to assure the quality of the processing result. As a solution a measurement method has been developed that allows to scan the powder density distribution of the entire powder-gas-flow. Contact Person Dipl.-Ing. Stefan Mann Phone +49 241 8906-321 stefan.mann@ilt.fraunhofer.de Fraunhofer Institute for Laser Technology ILT | |
| BOOTH 07 E100.CPC | Monitoring the Melt Pool Geometry at Laser Cladding Laser cladding is used almost exclusively on complex geometries, durable and high-valued components, e.g. for stationary gas turbines and aero engines. These parts have to fulfill high safety standards and very high quality and documentation requirements. Understandably, process documentation, monitoring and control methods play an important role here. The CPC system (Coaxial Process Control) developed at the Fraunhofer ILT/LLT is adapted to the cladding process combined with a process illumination by High-Power LEDs. The aim is to extract quality-relevant process information in-situ whilst laser processing by monitoring the melt pool geometry as a robust process parameter. This information should interrupt defective processes in time to initiate corrective processing strategies, and fulfilling the relevant quality assurance documentation requirements (DIN ISO 9000 ff., VDA 6.1), e. g. for safety-relevant components. Contact Person Dipl.-Ing. Stefan Mann Phone +49 241 8906-321 stefan.mann@ilt.fraunhofer.de Fraunhofer Institute for Laser Technology ILT | |
| BOOTH 29 E100.MB5 | Process Monitoring and Control during Hybrid Laser-arc Welding In current manufacturing, conventional arc welding processes, such as MIG/MAG and submerged arc welding, are mainly used to produce joints of metal sheets over a wide range of materials and wall thicknesses. Yet the manufacturers are facing problems like a low productivity and reliance on the skill of operators to change process parameters to maintain weld quality, particularly during changeovers, i.e., when material and/or wall thickness is changed. Hybrid laser-arc welding offers many advantages compared with conventional arc or laser welding. Producing deep penetration welds comparable with laser welds, and at the same time having an improved tolerance to joint fit-up when compared with laser welding. The coupling of the two processes - laser and electric arc welding - leads to an increased number of parameters and degrees of freedom, respectively. In the presented work a camera based coaxial monitoring system is employed to achieve controlled conditions for laser MIG/MAG hybrid welding processes. Contact Person Dipl.-Ing. Wolfgang Fiedler Phone +49 241 8906-390 wolfgang.fiedler@ilt.fraunhofer.de Fraunhofer Institute for Laser Technology ILT | |
| BOOTH 37 E100.DL1 | Process Observation in CO2 Laser Beam Cutting Trumpf Trulas 5030 is one of the fastest Flat-Bed Laser Beam Cutting Machines currently available. As part of the Cluster of Excellence at RWTH Aachen University, ICD D2.1 "Technology Enablers for embedding Cognition and Self-Optimisation into Production Systems", this machine was equipped with an optical sensor system that allows live observation of the process. A high-speed camera system coaxially coupled with the processing beam monitors the 2 millimetre interaction zone while the machine moves the processing unit at 200 metres per minute accelerating with 2g. Current works focus on strategies to analyse the acquired data in process to enable Self-Optimisation of the machine. Together with the Fraunhofer ILT and NLD, a system is developed that implements cognitive functions by means of a Controller Component and a Meta-Modelled Knowledge Base which willl lead to the Cognitive Laser Beam Cutting Machine. Contact Person Dipl. Ing. B. Eng. (hon) Ulrich Thombansen Phone +49 241 8906-320 ulrich.thombansen@ilt.fraunhofer.de Fraunhofer Institute for Laser Technology ILT | |
| BOOTH 10 E100.CPC | TCP-Seam Tracking TeThe first industrial system for simultanoues TCP- and seam tracking is shown. During longitudinal seam welding of pipes in industrial manufacturing plants, lacks of fusion often lead to production downtimes and returns. Lack of fusion in the weld seam that has not been identified can lead to a failure of the seam in further processing. The reason for the defect is a lateral shifting of the groove in relation to the laser beam, which can be caused by the pipe twisting, the joining edges being out of alignment, poor initial setting of the plant or of the seam-tracking sensor, and shifting of the laser beam owing, for example, to thermal influence. While the first two effects can be controlled and corrected using conventional seam-tracking sensors and proper tracking, thermal effects result in a shifting of the beam within the beam guiding system. The principle suggests that this can be neither identified nor corrected by conventional seam tracking. So the aim is to ascertain the beam’s position relative to the seam, in order to have the seam tracking correspond of the TCP. xt Contact Person Dipl.-Ing. Peter Abels Phone +49 241 8906-428 peter.abels@ilt.fraunhofer.de Fraunhofer Institute for Laser Technology ILT |
