Automated welding

WeldQAS - Exampels of use


Process optimisation - Example of a process optimized badly

  • Two robots which shall respectively weld the same seam at two workpieces were programmed dissimilarly.
  • Although the seams are visually almost identical, they have different fusion penetrations.
  • Our QAS monitoring system recognizes this dissimilar programming of the robots.

Optimization by means of documentation while MIG – soldering

  • fluctuations and trends can be recognized by statistical analyses(e.g. because of wear).

Robot guided MAG-welding of exhaust systems (use of the ThermoProfilScanner)

Task: Proof and recognition of visible welding inconsistencies during MAG-welding.
Customer requested for a simpler and more robust handling as provided by an existing optical seam measuring system (after welding).
Proof of visible burn through.


offset to the torch: 40 mm
scan frequency: 100 Hz
resolution:  0,9 mm
work distance: 60 mm
purging gas: 3 l/min
welding speed: 60 cm/min
no water cooling




Welding fault: geometric deviations and seam necking of 0,8 – 2 mm

Plasmatron brazing of car bodies (use of the ThermoProfilScanner)


Recognition of visible welding inconsistencies as fusion faults and pores larger than 1 mm.


offset to the torch: 7 mm
scan frequency: 100 Hz
resolution: 0,9 mm
work distance: 130 mm
purging gas: 3 l/min
welding speed: up to 3 m/min
no water cooling    

The immediate fault recognition is prevention the part being used for the total body assembly..The resulting cost savings amount to 1000 EUR per detected fault .

Welding fault: large fusion fault

Right at the start, the seam is shifting towards the edge, than break up and fusion fault.

Welding Fault: small fusion faults

  • Fusion fault  caused by defective electrode
  • Increasingly unstable seam progression towards the end of seam

Welding Fault: No fusion during first 5 mm