VisionLine for welding

Stranded wire connections require extremely precise positioning of the laser beam - even the slightest deviation can compromise 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. The result: consistently high quality with significantly shorter cycles.

Control units that are becoming smaller and more complex require highly reliable connections with low transition resistances. Any positioning deviation 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: minimized batch-to-batch variation and no rejects.

Hairpins for electric motors require optimum 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 the welding parameters. The no-code operating concept allows for quick programming without any knowledge of image processing. Enabling 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 transition resistances, microcracks, and short circuits. A defect in as many as 300 welds per engine results in the entire component being rejected.

VisionLine OCT Detect captures 3D geometry with micrometer 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 focus position of the laser. This affects the quality of the weld. Every geometric deviation must be detected and corrected on 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 millimeters - even minor welding deviations can lead to performance losses or material damage. Particularly critical: gaps between the pin and substrate. Complex geometries and clamping fixtures make measurement even more difficult.

VisionLine OCT Detect uses a coaxial measurement beam for 3D measurements - it can measure any welding location, even with shadowing effects. 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 downtimes. Every component must be inspected.

VisionLine OCT Check measures the welding depth in real time using optical coherence tomography (OCT). This allows you to maintain seamless quality controls even at high production speeds. This is how you 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 (aluminum, copper, nickel-iron) between the cell and 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 package must be 100 percent qualified - low transition resistance and mechanical stability are non-negotiable.

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

Stranded wires made up of many individual wires are often combined unevenly during welding. This leads to a higher transition 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 weld, 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.