Product

Information
Model JST Optical
Seam Tracker
Non-Contact Operation
Laser Sensor
High Precision
All Types of Weld Joints
Complete Range of Slides
Multi-Pass Capability
Introduction
Conventional seam tracking systems with tactile
probes have been used for many years and have
a proven record of success. There are, however, a
number of applications where the use of a probe
which must "feel" the weld joint can lead to irregular
and unreliable results. In these applications, it has
been traditional to resort to special probe designs
and to have the operator monitor the weld process
in order to take corrective action if the seam tracker
probe is seen to leave the joint.
The introduction of laser tracking permits automatic
joint tracking to be used in the more difficult joint
configurations. As the system functions with no
contact between the sensor and the joint, there is
no tendency for the system to run out of the joint.
The system is suitable for all types of joint design
and all arc welding purposes.

Description
The complete seam tracking system consists of the
following elements:
Laser Sensor
Seam Tracker Control
Pendant Control
Motorized Cross-Slide
All the elements of the system have been developed to be compatible. There is no need for you to
mix and match components from different manufacturers with all the problems that entails.

System Elements
Laser Sensor
The compact laser sensor is normally mounted on
or near the welding torch. It is of a robust design
and construction to function satisfactorily, even in
high current and heat environments. Units have
been used in applications with welding currents
up to 700 amps.
The sensor houses laser diodes with optics which
project a fan of visible laser light on to the work
piece. A CCD camera in the sensor, set at a triangulation angle to the laser diodes, receives a
reflection from the surface of the part which is a
contour map of the joint geometry. Using triangulation permits not only the horizontal features to be
detected, but also the height (sensor to work piece
distance) to be determined.
The sensor is supplied complete with a spatter shield
with disposable protective window. This protects
the laser diodes and the camera from the heat
and fumes of the welding arc. Dry compressed air
can be fed to the sensor to assist in cooling and to
keep the protective window free of fume buildup.
For high heat applications, a water cooled sensor
mount is included to integrate with an optional or
customer supplied water chiller.

15 Goodyear St, Irvine, California 92618 U.S.A. Tel: (949) 951-1515 Fax: (949) 951-9237

MODEL JST OPTICAL SEAM TRACKER

The sensor has an aluminum housing and is available in three versions. The version type is based
upon the width of the laser stripe. The choice of
stripe width is important as this sets the "sensitivity" of
the tracking process. The narrower the stripe width,
the finer the detail which can be sensed. For close
butt joints of the type experienced in GTA welding,
the narrowest stripe should be used. This limits the
field of view. For weld joints with more pronounced
features, the wider stripe provides greater latitude
for finding and tracking the joint.
Sensors are available with stripe widths of ", 1"
and 2" (16, 35, and 65 mm). The sensor with the
smallest stripe width is capable of sensing features
as small as 0.005" (0.1 mm).

Seam Tracker Control

The control receives the video image from the
sensor. The control processes the information it
receives and translates it into corrective movements of the dual axis cross slide. The processing
is carried out in four main modules which function
as a harmonized package.
Video Acquisition Module
The video image from the camera in the sensor
is fed into a data acquisition board. This digitizes
and stores the image, and also runs a convolution
filter along each line of the video signal. The filter
"knows" the width and shape of a typical stripe,
and looks along each video line for the closest
matching feature.

Segmentation Module
This stage analyzes the stripe data from the acquisition board and divides it into lines. This is done using preprogrammed information about the slopes
(angles) to be looked for, and also by knowing the
size of the step or break to be expected based
upon the seam type being sensed.
The line
segmentation is based upon features which are
sensed, e.g. a step caused by a lap joint, a break
caused by the gap between sheets in a butt joint
or the angle sensed in a groove or fillet.
Comparator Module
This software section looks at the lines defined by
the segmentation software and determines which
lines form the seam. This is done by comparing
what is actually seen with a theoretical shape
which has been entered into the computer for this
type of weld joint.
Extractor Module
This software stage extracts the seam information
and, according to preprogrammed instructions,
sets the torch in its correct relative position with the
joint, either in the center or a different position.
Using this information, the control moves the slides
to maintain the correct relative position of the
welding torch.
The system is capable of working with different
joint configurations. The seam tracker control is
preprogrammed with a number of standard joint
geometries.

SCHEMATIC DIAGRAM

Note:
Video monitor and PC are
additional price options.

MODEL JST OPTICAL SEAM TRACKER

Pendant Control
The operator pendant control is supplied as standard with all seam tracking systems and includes
the following displays and controls:

CAMERA

Two line fluorescent display

Self-centering jog switches, left-right, updown
Start and stop pushbuttons
Laser on/off pushbutton with warning lamp
Seam pushbutton with lamp
Error pushbutton with warning lamp

The pendant operates in conjunction with the

seam tracker control and has different functions
according to the setting of the control selector
switch. In the RUN mode, the display changes
depending on whether the system is in standby or
tracking mode.

LENS
FILTER
LASER DIODES
LASER OPTICS

LASER
STRIPE

FEATURE
(LAP)

In the standby mode, the operator has control of

the following options through the pendant:

Choose the seam type

Jog the slides
Turn the sensor on and measure the seam
position
Adjust the laser brightness intensity
Teach the desired seam position
Start the operation of the seam tracker

In the tracking (active) mode, the operator has the

following controls and indicators:

Pressing either of the jog buttons offsets the

torch position relative to the preset position.
The display indicates the error in the seam position under the sensor head.
Pressing the seam button displays the current
seam type. If the jog button is pressed at the
same time, the seam type can be changed
even as the weld proceeds.
Pressing the stop button deactivates the slides
and turns off the laser. The system can be
started and stopped by a remote signal.
The display shows the number of images which
have been successfully captured to control the
tracking. This shows how accurately the unit
is tracking. The number should be higher than
80% unless the sensor is passing over a tackweld
or similar feature.

Motorized Cross-Slide
Because Jetline is a manufacturer of weld fixturing,
a large number of slide configurations can be used
with this seam tracking system. Unless otherwise
ordered, each optical seam tracking system is
supplied with a set of standard slides. These slides
permit cross seam and arc gap tracking to be carried out. Slides are available with various weight
capacities and stroke lengths to permit the right
slide for the job to be selected.

Schematic view of sensor head

Standard slides consist of a custom aluminum
extrusion fitted with hardened vee-way tracks. A
carriage rides on the tracks using hardened veeway wheels and is driven by a motor with tachgenerator which responds to signals from the seam
tracker control.
For nonstandard applications, the system can
be interfaced with longer slides and with Jetline
side beam tracks. Slides are available in tracking
lengths of up to 36" (900 mm). For applications
where the travel required is longer than this, a side
beam track can be used. These are available with
almost unlimited travel lengths. Long travel lengths
of this type are useful where the system is being
used to track the helical flights on extruder screws
and on augers. For other applications, the system
can be incorporated with Jetline weld head locators. These provide stroke lengths of up to 10 ft x
10 ft (3 x 3 m) and can therefore function as a very
large cross slide. This is an excellent feature for the
tracking of large contoured parts.
The system is available with the following standard
slides. For all nonstandard applications, please call
our customer support department.
Weight Capacity

Stroke

250 lbs (110 kg)

10x10 (250 x 250 mm)

250 lbs (110 kg)

5x5 (125 x 125 mm)

40 lbs (20 kg)

3x3 (75 x 75 mm)

MODEL JST OPTICAL SEAM TRACKER

Special Features

Specifications

The standard unit is suitable for all straightforward

tracking operations and will maintain the relative
position of the torch to the work piece in both the
cross seam and vertical direction.

Sensor Unit

Where the condition of the joint is variable or

where, in multi-pass welds, there is a variation of
fill, alternative systems are available which can
measure the joint and calculate the necessary
change in travel speed to achieve the necessary
fill. These systems use the same type of laser sensor and work in conjunction with the full range of
Jetline fixturing to ensure that the perfect weld is
achieved every time.

Choosing a seamtracker
The correct choice of seam tracker depends on
many variables. Optical seam tracking is the ideal
choice in many circumstances but there may be
applications where a different type of unit is ideal.
Jetline manufactures tactile as well as optical style
tracking systems and so has the correct type of
tracking system for most of your applications.
The following chart shows the comparison of various seam tracker types for different joint configurations.
Joint
Narrow Butt
Seam with tacks
Bends
Fillet
Seam Find
Adaptive Weld

Laser
Vision

Through Inductive Tactile

-Arc Capacitive Probe

5
5
4
4
4
5

1
3
5
5
2
2

5
1
1
1
2
0

2
2
4
5
5
0

5
5

2*
1*

1
1

2*
1*

Multi-Pass Welds
Initial Root
Fill Passes
5
4
3
2
1
0
*

Excellent
Good
Average
Poor
Inadequate performance
Not possible
Circumstances could improve performance

Laser diodes:

Two IR. lasers, 40mW, Class 3b

Wavelength typ. 670nm.
Laser optics:
Two miniature collimators with
beam shaping optics
Laser safety:
Hardware and software interlocks
Stripe width:
" (16mm) @ 2" (65mm) standoff
1" (35mm) @ 3" (75mm) standoff
2" (65mm) @ 3" (85mm) standoff
Camera type: CCD
Pixels:
742 horizontal x 582 vertical
Field of view: "(15mm) @ 2" (65mm) standoff
(Horizontal)
1" (30mm)@ 3" (75mm) standoff
2" (60mm)@ 3" (85mm) standoff
Depth of field: " (17mm) @ 2"(65mm) standoff
1" (35mm)@ 3" (75mm) standoff
3" (75mm) @ 3" (85mm) standoff
Cooling:
Compressed air - clean & cooled
Water @ 50oF - 85oF (10oC - 30oC)
Max temp:
105oF (40oC)
Dimensions:
4H x 1W x 2D, 12 oz
Control
Cabinet:
Imput voltage:
Frequency:
Power:
Dimensions:

Rack mount enclosure

115/230VAC single phase
50/60 Hz
400 Watt
16H x 20W x 22D, 65 lb
400x 520 x 575 mm, 30 kg)

Cross Slide
Stroke

in:
10x10
mm: 250x250
Capacity lb:
250
kg:
110
Height
in:
23
mm:
580
Width
in:
22
mm:
550
Depth
in:
9.5
mm:
240
Weight
lb:
80
kg:
36

5x5
125x125
250
110
18
450
17
430
9.5
240
65
30

3x3
75x75
40
18
12
300
11
280
5.5
140
18
14

See Jetline price list for complete ordering information

Distributed by:

15 Goodyear St., Irvine, California 92618 USA

Tel: (949) 951-1515 Fax: (949) 951-9237 E-mail: sales@jetline.com

Web Page: www.jetline.com www.cyclomatic.com

The right to make engineering refinements is reserved. Dimensions and specifications are subject to change without notice.

JST-04/2006