In today's industrial landscape, welding has evolved to be deeply integrated with modern technologies such as computers, information systems, robotics, advanced materials, and extreme structures. This integration has continuously challenged traditional manufacturing approaches. Within the realm of digital intelligent welding equipment, intelligent tracking technology plays a crucial role in ensuring precision during the welding process. Achieving accurate weld tracking is essential for maintaining the quality of automated welding, and sensors are at the core of this system.
Sensing technology is not only vital for improving welding quality but also for increasing production efficiency and enhancing working conditions. As a result, it stands as a key enabler of intelligent and automated welding processes. The development and application of tracking sensing technology have become central to the advancement of modern welding techniques.
**1. Development and Application of Tracking Sensing Technology**
In any weld tracking system, the sensor serves as the critical component that determines the overall accuracy of the system. Over time, welding sensors have evolved from basic mechanical and electromagnetic designs to more sophisticated arc and optical (visual) sensors. Among these, research on optical sensors has been particularly active both domestically and internationally.
**1.1 Mechanical (Probe) Contact Sensing**
Mechanical contact sensors operate by placing a metal probe on the edge of the weld pool. As the probe moves along the weld, it transmits position data to the control system, which then adjusts the welding gun's path accordingly. While this method offers simplicity, affordability, and resistance to arc interference, it suffers from limited data output, wear, and incompatibility with high-speed operations. Innovations like Scansonic’s wire-based tracking system have introduced non-wearing alternatives, enabling precise laser guidance during welding.
**1.2 Ultrasonic Sensing**
Ultrasonic sensors use sound waves to detect deviations in the weld seam. By emitting and receiving ultrasonic signals, they can provide two-dimensional deviation data in real time. Researchers like Hu Shengyi from Tianjin University have focused on improving signal transmission and reducing noise interference. Despite their advantages—such as low cost and high precision—ultrasonic sensors face challenges related to signal loss and sensitivity to noise.
**1.3 Arc Sensing**
Arc sensing leverages changes in current and voltage within the welding arc to determine the position of the weld seam. It eliminates the need for additional sensors, offering real-time feedback and flexibility. Widely used in the 1990s, arc sensing remains a popular choice due to its cost-effectiveness and reliability.
**1.4 Visual Sensing**
Visual sensing technology has gained significant traction, as over 80% of a welder’s decision-making relies on visual input. Active and passive vision systems offer non-contact, high-precision detection, suitable for various joint configurations. Linear array CCDs, laser-based structured light, and multi-camera systems are commonly used. These systems allow for real-time tracking, adaptive control, and defect detection, making them highly promising for future applications.
**2. Future Trends in Tracking Sensor Technology**
As digital and networked technologies continue to advance, tracking sensors are expected to become faster, smaller, and more integrated. Multi-functional sensors will combine features such as geometric measurement, real-time tracking, and post-weld inspection. Additionally, the integration of multiple sensors—such as combining laser vision with arc or ultrasonic sensing—will enable more comprehensive monitoring and control.
Networking capabilities will also play a key role, allowing sensors to communicate seamlessly with robots, PLCs, and other systems. This will support intelligent, real-time manufacturing processes and improve overall efficiency.
**3. Conclusion**
The evolution of tracking sensing technology is shaping the future of welding, moving it toward greater intelligence, automation, and precision. From pre-weld positioning to post-weld inspection, these sensors ensure consistent quality and performance. With ongoing research and technological advancements, welding is becoming increasingly "visual" and "smart," paving the way for next-generation manufacturing solutions.
**About the Author:** Zhang Wei is an associate professor at Shanghai Jiaotong University, holding a doctorate in engineering and serving as a master tutor. His research focuses on mobile welding robots, laser processing, welding automation, and laser vision sensing. He has received numerous awards for his contributions to the field and has published over 40 academic papers.
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