VisionLine for welding

Strand connections require extremely precise positioning of the laser beam – even the slightest deviation can impair the result. At the same time, cycle times must be reduced.

VisionLine Detect automatically positions the laser beam on the wire in the camera image. The optional AI filter compensates for differences in contrast between different materials. This results in consistently high quality with significantly shorter cycles.

Control units that are becoming increasingly smaller and more complex require extremely reliable connections with low contact resistance. Any deviation from the specified position leads to failures, recalls, and high costs.

VisionLine Detect detects geometric features, checks limit values, and corrects the laser position in real time. The optional AI filter helps with shadowing and different oxidation states. Result: minimised production variation, no rejects.

Hairpins for electric motors require optimal conductivity, short-circuit protection, and mechanical strength – all while producing more than 110 welded hairpins per minute.

VisionLine Detect detects every pin in milliseconds and adaptively adjusts welding parameters. The no-code operating concept allows for quick programming without any knowledge of image processing. This enables you to achieve maximum productivity and precision.

Hairpins must safely conduct more than 500 amps on a continuous basis. Differences in the height of the pin ends cause soldering defects – increased contact resistance, microcracks, and short circuits. A single defect in up to 300 welds per motor results in the entire component being rejected.

VisionLine OCT Detect captures 3D geometry with micrometer-level precision. It measures height differences before welding, immediately detects critical deviations, and prevents rejects by making corrections early on.

Differences in the surface heights of modern battery packs shift the laser's focus position. This adversely affects the quality of the weld. Every geometric deviation must be detected and corrected – for every single component.

VisionLine OCT Detect measures the working distance and gap before welding and adjusts the focus position in real time. The result: consistent weld quality, higher productivity, and no rejects.

Copper contact pins have surfaces measuring only a few millimetres – even slight welding deviations can lead to performance losses or material damage. The gaps between the pin and the substrate are particularly critical. Complex geometry and clamping fixtures make measurement even more difficult.

VisionLine OCT Detect uses a coaxial measurement beam for 3D measurements – it can measure anywhere welding takes place, even in shaded areas. It reliably measures gap dimensions and helps prevent costly rejects.

Even slight variations in welding depth can damage the components underneath – which reduces the range of electric vehicles and leads to costly downtime. Every component must be inspected.

VisionLine OCT Check measures welding depth in real time using optical coherence tomography (OCT). This allows you to maintain seamless quality control even at high production speeds. This is how you can ensure the quality and reliability of every single component and avoid rejects.

Battery cell connections in modules and packs must be reliable and safe. The combination of different materials (aluminium, copper, nickel-iron) between the cell and the current conductors/busbars further complicates the joining process.

VisionLine OCT measures and monitors the welding depth of each joint in real time. Every weld is fully documented and traceable – maximum safety through transparent process control in modern battery manufacturing.

Hundreds of cell connectors per pack must be 100 percent compliant – low contact resistance and mechanical stability are non-negotiable.

VisionLine Inspect inspects every weld seam after the process is complete. An AI model detects the seam, and a measurement algorithm checks the length, width, and clearance against your specified limit values. You receive immediate feedback, and all data is traceable in the TRUMPF Quality Data Storage System (QDS).

Strands made up of many individual wires are often not properly secured during welding. This leads to higher contact resistance, overheating, and a shorter service life – which is particularly critical in complex electronic units.

VisionLine Inspect automatically inspects every weld seam. AI detects the seam, and the measurement algorithm compares it to limit values. You can spot errors immediately, identify trends, and integrate quality data directly into your production systems.