Definition of requirements for robust seam-tracking in robotic laser welding applications

The increasing adoption of robotic laser welding highlights the need for robust seam-tracking systems to ensure precision and adaptability. Current methods struggle with fixturing errors, part-to-part variations, thermal deformation and the need for precise alignment of the laser beam, especially in three-dimensional welding scenarios. Laser welding is particularly sensitive to variations in joint morphology and material reflectivity, requiring advanced solutions to maintain high welding quality. Spatial beam shaping techniques, based on beam oscillation or “wobbling”, partially mitigate these issues by accommodating variable joint gaps and high-reflectivity materials. However, solutions, capable of real-time trajectory planning and adaptive process control, are essential to meet the requirements of this technology. This work presents a comprehensive analysis of the technological and computational requirements for seam-tracking operations, providing a foundation for developing systems capable of operating at high welding velocities, while ensuring quality and minimizing rework, paving the way for a more-effective implementation in smart-manufacturing.