Automated inspection of welding seams

Bead Eye

The new Bead Eye is a visual weld inspection system - both hard- and software solution.

It offers improved traceability through full automation of manual visual inspection. Due to the automation process a labor saving is achieved - the visual inspection previously carried out by the operator is no longer necessary leading to a reduction in the operator‘s workload. Traceability is also improved. The newly developed automated inspection assesses the weld geometry and collects the inspection data for further processing.

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Key features of Bead Eye

Key features

Automated inspection

Exact evaluation

Transparent traceability

Panasonic's Automated Inspection Solution of Welding Seams - Bead Eye

The new Bead Eye is a Visual Weld Inspection system. Both hard- and software solutions offer improved traceability through full automation of manual visual inspection. Due to the automation process a labor saving is achieved - the visual inspection previously carried out by the operator is no longer necessary leading to a reduction in the operator‘s workload. Traceability is also improved. The newly developed automated inspection assesses the weld geometry and collects the inspection data for further processing.

Bead Eye (Visual weld inspection solution) Features

Inspection logic #1: Master comparison inspection

Setting up is easy because it is a comparison inspection to the master data.

It compares the target products to the pre-set master data, and judges pass/fail based on the concordance rate.

It is not possible to identify the type of welding defect or calculate design values such as bead leg length.
Defects that do not easily show a change in the matching rate (such as sputtering or extremely small holes) may not be detected.
If the inspection area is outside the sensor's measurement range, point cloud data may be missing, and the inspection may not be performed correctly.
The sensor cannot detect defects (such as holes) that the laser beam penetrates.

_{*The above limitations apply on a case-by-case basis, and prior verification is always required even within the limits.}
_{*Defects that cannot be identified from the bead shape, such as internal defects and insufficient penetration, cannot be detected.}

Inspection logic #2: AI inspection

The AI engine that has been trained at Panasonic will not miss the welding defects difficult for automatic visual inspection before.

AI learns the shape of the defects and judges its type and position. It can inspect the smallest defects easily.

_{* Actual judgment result shows the AI inspection and master comparison inspection in one image.}
_{* The AI engine used in this system has already been trained and customers cannot perform additional training.}
_{* Please read the limitations and other details here.}

If multiple defect factors overlap, only one of them may be detected.
If welding defects are too close together, there is a risk that multiple welding defects may be detected as a single defect.
Verification with actual workpieces and jigs is required. (The detection range for each welding defect will be discussed.)
AI inspection can only inspect linear weld beads (curved welds are not supported).
Inspection is possible using only arc welding.
Welded joints can only be inspected in the following shapes:
(1) Overlap fillet joints (2) T-shaped fillet joints (3) Butt joints. Please contact us separately for flare joints, etc.
This does not apply to beads with a scale-like pattern.

Customer benefits

A wide range of welding defects can be detected by the robot by combining AI inspection and master comparison inspection.

	Inspection logic
Defects	[1] Master comparison inspection	[2] AI inspection *	Bead Eye （[1]＋[2]）
Comparison with master	✓		✓
Chipping of bead	✓		✓
Out-of-line bead	✓		✓
Excess/under weld metal reinforcemen	✓		✓
Over/under bead width	✓		✓
Over/under bead length	✓		✓
Perforation		✓	✓
Pit		✓	✓
Undercut		✓	✓
Spatter		✓	✓

_{*Panasonic proprietary technology}

Collaboration (co-creation)

We will continue to accelerate co-creation and contribute to the development of the industry by addressing pressing issues such as improving short of labor and processing quality.

Precautions Upon Purchase

Please make sure to read the precautions below before purchasing Bead Eye.

Applicable models are TM/TL/TS/ LA-series robots connected to G3 or TAWERS (WG3/WGH3) type controller.
Please contact your nearest sales office for details.
This inspection function is only to inspect welding beads of CO₂/MAG welding using mild solid wire.
This inspection function is capable of performing ideal inspection by conducting various settings and teaching suitable to the applied workpiece, processing conditions and production facilities. This product does not guarantee the quality of the inspected workpiece.
It is not applicable to other purposes, such as inspection for MIG welding, TIG welding and laser welding.
This inspection function is capable of performing ideal inspection by conducting various settings and teaching suitable to the applied workpiece, processing conditions and production facilities. This product does not guarantee the quality of the inspected workpiece.
Users of this product should guarantee the final quality of the workpiece.
It cannot be used in an environment where strong ambient light, such as CO₂/MAG/MIG/TIG welding, exists in the same work area.