Market Application Background
In industrial manufacturing, welding technology determines product quality and production efficiency. Traditional methods cannot meet the high precision, high speed, and high flexibility requirements of intelligent manufacturing. Therefore, laser-based flying welding technology, which combines robotic arms with galvanometers, has emerged, driving a revolutionary breakthrough in manufacturing. In the era of Industry 4.0, this technology will become a core competitive advantage in intelligent manufacturing, becoming the mainstream choice in the market due to its superior performance and wide range of applications.
What is laser-in-flight welding?
Laser welding, a non-contact process, utilizes a high-energy laser beam to scan the workpiece surface at high speed to complete precision welding. Compared to traditional technologies, it has significant advantages such as no mechanical wear, zero thermal deformation, ultra-fast processing speed, and high precision, making it particularly suitable for manufacturing complex curved structures, thin-walled materials, and precision parts.
Pain points of traditional solutions on the market
Traditional laser welding uses a point-by-point welding method, and current traditional laser welding solutions have three major pain points:
Efficiency bottleneck: Point-by-point welding is limited by the response speed of the mechanical motion system, resulting in a long processing cycle and restricting capacity improvement;
Limitations of flexibility: The large and redundant structure of the equipment makes it difficult to weld complex workpieces, and three-dimensional surface welding has obvious limitations;
Precision defects: The cumulative error of the mechanical motion system directly affects the trajectory accuracy, making it difficult to meet the requirements of high-precision welding.
Positive motion technology solutions
Addressing the pain points of current market processes, Zheng Motion Technology has launched a robotic arm-laser galvanometer collaborative flying welding solution.
The robotic arm, with its multi-degree-of-freedom capabilities, solves the challenge of welding complex workpieces at multiple angles; the galvanometer, through high-speed scanning, precisely controls the laser focus, achieving millisecond-level welding response. In collaborative operation, the robotic arm positions and moves the workpiece, while the galvanometer rapidly adjusts the laser path, enabling a dynamic "welding while moving" welding mode. This collaborative approach not only significantly improves welding efficiency but also substantially reduces equipment wear and energy consumption. It provides enterprises with a high-efficiency, high-precision, and highly flexible low-cost welding process.
01. Laser galvanometer motion controller in laser flying welding application of robotic arms
▲Schematic diagram of a robotic arm laser galvanometer flying welding machine▲
Positive motion technology robotic arm laser galvanometer flying welding hardware solution
Demonstration Case of Flying Welding Application of Robotic Arm with Laser Galvanometer in Positive Motion Technology
Based on the ZLaserMarking laser welding system with positive motion control platform, it integrates power waveform control and gradual in/out process functions to achieve high-precision positioning and high-speed dynamic response output for laser welding within the processing domain.
ZLaserMarking laser welding system core functions
1. High-precision calibration of scanning galvanometer
By acquiring actual coordinate data of laser marking using a high-precision camera and comparing it with theoretical coordinates, automatic calculation and correction of galvanometer distortion error can be achieved.
2. Real-time collaborative control of the robotic arm system
A real-time data channel between the galvanometer controller and the robot controller is constructed based on the high-speed EtherCAT bus communication protocol. Through spatial coordinate mapping, the robot's world spatial coordinate system is converted into the feedback position of the laser galvanometer controller axis in real time.
3. Synchronous control of scanning galvanometer and robotic arm
Based on a feedback axis synchronous following control algorithm, a high-precision synchronization mechanism for galvanometer scanning and robot arm motion is constructed. By superimposing the robot arm's motion trajectory with the galvanometer scanning path, the galvanometer deflection angle is dynamically adjusted to compensate for robot arm positional offset. This ensures that the laser beam maintains stable focus during high-speed movement, achieving precise forming of complex weld seams in three-dimensional space.
4. Real-time control of laser power
The laser power is adjusted in real time based on the material thickness, properties, and welding rate to ensure that the weld penetration and width meet the process requirements.
Laser flying welding operation process
Robotic arm laser galvanometer flying welding operation processing effect
Advantages of the solution
1. High speed and high precision: Integrating advanced control algorithms and high-performance hardware, it achieves rapid response and precise positioning accuracy of the laser beam, ensuring that the welding process is both efficient and precise.
2. Flexible and easy to use: Supports multiple motion modes, and can easily achieve welding of complex trajectories such as straight lines, arcs, and three-dimensional trajectories to meet various welding needs.
3. Stable operation: It has comprehensive fault diagnosis and protection functions to ensure continuous and stable operation and effectively reduce the risk of downtime.
4. Ecosystem Expansion: Equipped with standardized industrial interfaces and a modular development platform, it supports rapid integration with multiple brands of lasers and automated equipment, facilitating the construction of flexible production lines.
02. Open-type laser galvanometer motion controller ZMC408SCAN-V22
The ZMC408SCAN-V22 stand-alone laser galvanometer motion controller integrates laser control, galvanometer control, and bus axis/pulse axis control, helping you achieve a highly efficient and precise EtherCAT bus motion control + laser galvanometer solution.
● Optional 6-64 axis motion control (pulse + EtherCAT bus);
● Two laser galvanometer interfaces with feedback, one dedicated laser power supply interface for LASER and one for FIBER;
● Supports 1D/2D/3D PSO functions, enabling visual imaging, precision dispensing, and laser energy control;
● The integration of laser galvanometer control and motion control allows for the flexible construction of laser processing systems with multi-axis linkage and other methods;
● Multi-dimensional position synchronous output (PSO), onboard 24 general-purpose inputs and 20 general-purpose outputs, including 4 high-speed color mark latches, 4 PSOs and 8 PWM outputs.
