Remote laser welding with seam tracking and inline inspection
Precise seam tracking in real time for fast welding processes
For highly dynamic laser welding processes with a large working distance, the WeldMaster Scan & Track & Inspect enables remote welding without mechanical contact - with stable process control and assured welding quality.
The seam position and gap situation are detected optically and tracked via fast control of the laser beam. This enables reproducible results to be achieved even at high speeds and with varying components - particularly with aluminum, but also with steel and thick sheet applications with high laser power. The process can be implemented without additional wire, which reduces the amount of material used and increases cost-effectiveness.
At the same time, an inline inspection is carried out before, during and after welding (pre-, in-, post-process). Process and seam information is continuously recorded and evaluated so that the welding quality is monitored and assured at all times.
Highest process speed for remote welding
Process speeds of more than 6 m/min can be achieved thanks to the optical pre-positioning and the highly dynamic beam guidance. The large working distance enables collision-free processing and reduces non-productive times - ideal for highly automated series processes with short cycle times.
Stable welding processes despite component tolerances
Gap changes due to component tolerances or heat input are detected in real time and compensated for on the fly. Continuous tracking of the laser beam ensures stable process control and consistent seam quality - even with varying components and demanding materials.
Integrated inline inspection for assured quality
The weld seam is monitored before, during and after the process (pre-, in-, post-process). Process and quality data are continuously recorded and evaluated so that deviations are detected at an early stage and the welding quality is reliably assured - without additional test steps.
Applications of WeldMaster Scan & Track & Inspect
WeldMaster Scan & Track & Inspect is used in laser welding processes where high dynamics, great accessibility and stable welding quality are required. Typical applications are
Remote laser welding with a large working distance - The laser works without mechanical contact with the component. This reduces the risk of collision and allows complex geometries to be processed flexibly.
Welding of aluminum structures with varying gaps - Tolerances often lead to gap deviations in aluminum components. The system compensates for these in real time and ensures stable welding processes.
Highly dynamic series production with short cycle times - Thanks to the high process speed, WeldMaster Scan & Track & Inspect is particularly suitable for automated production lines with high quantities.
Welding of steel and thick sheet metal components with high laser power - The process remains stable and controllable even with power-intensive applications, for example up to 24 kW.
Processes with integrated quality monitoring - Inline inspection enables continuous evaluation of the weld seam during production - without additional inspection steps.
Typical markets
The system is primarily used in industries in which automated laser welding processes with high demands on speed, quality and process stability are implemented.
- Automotive industry
Used for body structures, aluminum parts and lightweight components. Particularly relevant for remote welding processes in highly automated production lines.
- E-mobility / battery production
Welding of structural components and housings with high demands on tightness and quality.
- Machine and plant construction
Processing of complex components with varying geometries and requirements for reproducible welding processes.
- Heavy industry and steel processing
Practical example: Remote welding at AUDI
The potential of remote laser welding is particularly evident when used in automotive production - for example in the manufacture of door structures for the Audi A8.
The use of WeldMaster Scan & Track & Inspect (also known as WeldMaster ScanTracker) has made production processes significantly more efficient. The large working distance enables collision-free welding, while the high process speed contributes to a significant reduction in cycle times. At the same time, the integrated inline inspection ensures continuous quality monitoring during the ongoing process.
The result is measurable benefits for series production:
- 26 % reduction in investment costs
- 95 % reduction in operating costs
- 50% lower energy input per component
- 25% reduction in CO₂ emissions
This makes it clear: remote laser welding with integrated process control not only enables higher productivity, but also more sustainable and economical production.
Technical data
- Real-time image and data processing
- Support for all common fieldbus interfaces
- Wavelength 1010–1120 nm
- Laser power up to 24 kW
- Max. scan width +/- 12 mm (at Ff = 300 mm and NA 0.09)
- Protection class IP54
We need your consent to load the form!
We use Marketing Cloud Account Engagement (Pardot) Forms to embed content that may collect data about your activity. Please review the details and click in the Pardot box to accept the service and see the content. If the form is not displayed correctly, please click once more on Download the data sheet now.
Do you still have any questions or would you like an offer? Then contact us!
