The status quo and development trend of intelligent tracking sensor technology

In today’s industrial landscape, welding is deeply integrated with modern technologies such as computers, information technology, robotics, advanced materials, and extreme structures. The increasing demands of the industry continuously challenge traditional manufacturing models. Among these, digital intelligent welding equipment has emerged as a critical component, with intelligent tracking technology playing a vital role in ensuring precision and quality during the welding process. Accurate weld tracking is essential for maintaining the quality of automated welding. At the heart of this system lies the sensor, which is the most crucial element in an automatic seam tracking system. As intelligent and automated welding becomes a key method for enhancing welding quality, boosting production efficiency, and improving working conditions, sensing technology has become a cornerstone in achieving intelligent and automated welding. **1. Development and Application of Tracking Sensing Technology** Sensors are the core of any weld tracking system, directly determining the accuracy of the entire process. Over time, welding sensors have evolved from simple mechanical and electromagnetic designs to more advanced arc and optical (visual) sensors. In recent years, research on optical sensors has been particularly active, driven by their potential for high precision and adaptability. **1.1 Mechanical (Probe) Contact Sensing** Mechanical contact sensors work by placing a metal probe on the edge of the weld pool. As the probe moves along the weld, it sends signals to the control system, which then adjusts the welding gun’s path. This system offers simplicity, low cost, and resistance to arc interference. However, it suffers from limited data, wear, and incompatibility with high-speed welding. Scansonic, a German company, introduced a unique approach using a wire as both the material for the weld and the tracker. The wire is pressed into the joint and melted under laser focus, enabling precise positioning and guiding the laser head along the weld. This method eliminates wear and improves accuracy. **1.2 Ultrasonic Sensing** Ultrasonic sensors use sound waves to detect weld deviations. They are known for their high precision and affordability. However, they are sensitive to noise and require careful design to minimize signal loss and improve real-time performance. Compared to optical sensors, they offer lower computational demands but also lower tracking accuracy. **1.3 Arc Sensing** Arc sensing measures changes in current and voltage during the welding process to determine the position of the weld. It is widely used due to its simplicity, real-time performance, and lack of additional hardware. Arc sensors are especially effective in low-cost automation and have been extensively researched and applied in various welding systems. **1.4 Visual Sensing** Visual sensing uses cameras and light sources to capture images of the weld area. It provides rich data, is non-contact, and offers high sensitivity and anti-interference capabilities. It is suitable for various groove shapes and can monitor both seam tracking and welding quality. Visual sensors come in different types, including linear and area array CCDs, as well as laser-based systems. For example, linear array CCDs can capture lateral profile data and provide critical information for intelligent control. Active vision sensors, often using lasers, are particularly useful in overcoming arc and smoke interference. Passive vision sensors, on the other hand, rely on arc or ambient light, offering advantages in direct monitoring without lead detection errors. **2. Future Trends in Tracking Sensor Technology** As digital and information technologies advance, future tracking sensors will be faster, smaller, more integrated, and networked. Multi-functional integration allows sensors to not only track seams but also monitor welding parameters and detect defects. Multi-sensor fusion combines different sensing methods to enhance accuracy and adaptability. Networking enables seamless communication between sensors, robots, and control systems, forming a smart manufacturing environment. These trends highlight the growing importance of intelligent and automated welding, where sensors act as the "eyes" of the process, making welding more visual, precise, and efficient. **Conclusion** With the advancement of digital and information technologies, tracking sensors are evolving toward multi-functionality, information fusion, and networking. They enable comprehensive quality monitoring throughout the welding process, from pre-weld positioning to post-weld inspection. The development of visual sensors, in particular, has transformed welding into a more intelligent and visual process, paving the way for the future of welding technology. Author: Zhang Wei, associate professor at Shanghai Jiaotong University, with a doctorate in engineering and extensive research experience in mobile welding robots, laser processing, and welding automation. He has received multiple awards for his contributions to science and technology.

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