Process and Beam Control

Our Service

Monitoring systems in industrial production are required because there are such high quality and productivity requirements in material processing with laser radiation. Fraunhofer ILT develops and implements a broad spectrum of technologies for inline process monitoring and control, in particular for increasing product and process qualities. Pyrometric and camera-based systems with analysis tools for heat or plasma radiation as well as laser-based measuring processes are used here and allow efficient online process monitoring. Faulty components or processes can be detected quickly and downstream quality controls can be replaced.

Robust thickness measurement system »bd-2« (two interferometric sensors and a C-frame).
© Fraunhofer ILT, Aachen, Germany.

Robust thickness measurement system »bd-2« (two interferometric sensors and a C-frame).

Alignment of powder focus, position of the processing laser radiation (green) and measuring radiation of the "bd-1" (red).
© Fraunhofer ILT, Aachen, Germany.

Alignment of powder focus, position of the processing laser radiation (green) and measuring radiation of the "bd-1" (red).

Experimental set-up for simulated heating of FKV tapes.
© Fraunhofer ILT, Aachen, Germany.

Experimental set-up for simulated heating of FKV tapes.

Not only is acquiring process information important, but it is also crucial to record the process flow through intermediate and trend information. To accomplish this, process sensor technology is an important element that can optimize laser machining processes. To use corresponding sensors efficiently and stably, the industry requires a high degree of process understanding. For this purpose, Fraunhofer incorporates its know-how and experience in process development and modeling, system technology and beam-source development into developing and integrating innovative systems for process monitoring. In order not to limit the process-specific advantages of laser material processing, the institute uses non-contact measuring methods such as spectroscopy, triangulation, pyrometry, thermography and camera-based methods.

When they evaluate the process data, the scientists use special analysis processes to meet the high requirements in laser material processing in real time. Here, modern AI-based processes make it feasible to sharpen process classification, among others.

The services offered include feasibility studies, customer-specific development and implementation of process visualization and process diagnostics, process monitoring and process control, process and sensor integration in industrial manufacturing environments, and individualized consultation.

Process and Beam Control

  • Monitoring, control and closed-loop control of laser manufacturing processes for many laser applications at a vast variety of wavelengths
  • Process monitoring using spatially and temporally high resolution camera systems and fast hardware-based real time image processing
  • Feasibility studies of process monitoring and control
  • Integration of process monitoring and control in existing manufacturing facilities
  • Development of customized sensors such as simultaneous TCP and seam tracking during laser welding or position and kinematics measurements at remote and robotic applications
  • Construction of networked multi-sensor systems, e. g. for computer-aided production data acquisition and multi-parameter closed-loop control

Brochures and Flyers

Our brochures and flyers offer a quick view onto the service portfolio “Process and Beam Control“. Find more detailed information in the “project results“ tab.

 

Brochure “Process Control in Laser Materials Processing“

 

Brochure “System Technology for Laser Material Processing“

Publications

Özmert, A., Neisser-Deiters, P., Drenker, A.:
Detectability of penetration depth based on weld pool geometry and process emission spectrum in laser welding of copper
Proc. SPIE 9135, 91351W (7 S.) (2014)

Thombansen, U., Ungers, M.:
Cognition for robot scanner based remote welding
Proc. SPIE  8963, 89630N (8 S.) (2014)

Thombansen, U., Gatej, A., Pereira, M.:
Tracking the course of the manufacturing process in selective laser melting
Proc. SPIE 8963, 89630O (7 S.) (2014)

Oezmert, A., Drenker, A., Nazery, V.:
Detectability of penetration based on weld pool geometry and process emission spectrum in laser welding of copper
Physics Procedia  41, 502-507 (2013)

Thombansen, U., Purrio, M., Buchholz, G., Hermanns, T., Molitor, T., Willms, K., Schulz, W., Reisgen, U.:
Measurement of process variables in melt based manufacturing processes
In: ISMTII 2013 - The 11th International Symposium on Measurement Technology and Intelligent Instruments
Aachen /Braunschweig July 1st-5th 2013 (6 S.) (2013)

Thombansen, U., Beckers, M., Buchholz, G., Hermanns, T., Molitor, T.,
Willms, K., Reisgen, U., Schulz, W.:
Signal processing for self-optimising manufacturing systems in
laser-cutting and gas-metal-arc-welding

In: 1st Joint International Symposium on System-Integrated
Intelligence, 114-116, (2012)

Frank, S., Ungers, M., Rolser, R.:
Coaxial control of aluminium and steel laser brazing processes.
Phys. Proced. 12, Part A, 752-760, (2011)

Franz, C., Abels, P., Rolsner, R., Becker, M.:
Energy input per unit length - high accuracy kinematic metrology in laser material processing.
Phys. Proced. 12, Part B, 411-420, (2011)

Franz, C., Abels, P., Merz, M., Singpiel, H., Trein, J.:
Real-time process control by machine vision.
ICALEO 30. Int. Congr. on Applications of Lasers and Electro-Optics, October 23-27, 2011. Paper 205, 6 S., (2011)

Franz, C., Singpiel, H., Trein, J.:
Tracking the contour.
Laser Technik J. 8, Nr. 5, 41-44, (2011)

Gatej, A., Thombansen, U., Loosen, P.:
Kombinierte thermo-optische Simulation für optische Systeme .
DGaO-Proc. 112, 2 S., (2011)

Gatej, A., Thombansen, U., Loosen, P.:
Simulation des thermischen Linseneffekts in hochbelasteten Lasersystemen.
Photonik 5, 54-56, (2011)

Thombansen, U., Schüttler, J., Auerbach, T. [u.a.]:
Model-based self-optimization for manufacturing systems.
Proc. of the 2011 Int. Conf. on Concurrent Enterprising (ICE 2011). Eds.: K.-D. Thoben [u.a.] Piscataway, NJ : IEEE 2011. 9 S.

Thombansen, U., Auerbach, T.:
Der Weg zu Selbstoptimierenden Fertigungstechnologien.
In: Brecher, C. (Hrsg.): Integrative Produktionstechnik für Hochlohnländer, pp. 849-909, (2011)

Fiedler, W., Drenker, A., Kaierle, S.:
Process monitoring and control during hybrid laser-arc welding of medium section steel sheets
ICALEO 2010. 29th International Congress on Applications of Lasers & Electro Optics, Anaheim/Ca., Paper 205, 7 S., (2010)

Franz, C., Abels, P.:
Measuring welding velocity at tool center point
ICALEO 2010. 29th International Congress on Applications of Lasers & Electro Optics, Anaheim/Ca., Paper 1909, 8 S., (2010)

Kaierle, S., Kowalick, K., Regaard, B.:
Laser process monitoring: The next generation approach in industrial application.
PICALO 2010, March 23-25, 2010
4th Pacific International Conference on Applications of Lasers and Optics. Wuhan, Peoples Republic of China, Paper 405, (2010)

Kaierle, S., Ungers, M., Franz, C., Mann, S., Abels, P.:
Understanding the laser process
Laser Technik J. 7, Nr 2, 49-52, (2010)

N. Stache, J. Dieckelmann, R. Firnich, J. Gedicke, P. Abels, A. Olowinsky, T. Aach:
High speed video-based melt pool surveillance in laser spot welding
Proc. of the 27th Int. Congress on Applications of Lasers & Electro-Optics 2008, ICALEO, Temecula, CA, USA, October 20-23, (2008)

S. Kaierle, P. Abels, W. Fiedler, S. Mann, B. Regaard:
Online-Qualitätssicherung für das Laserstrahlschweissen
MB-Revue 132-135, (2008)

S. Kaierle:
Process monitoring and control of laser beam welding
Laser Technik J. 5, Nr. 3, 41-43, (2008)

P. Abels, A. Roesner, S. Kaierle, S. Mann, A. Olowinsky, N. Matsuo, A. Hino:
Various process monitoring approaches of transparent thermoplastics laser beam welding
Proc. of the 27th Int. Congress on Applications of Lasers & Electro-Optics 2008, ICALEO, Temecula, CA, USA, 99-104, (2008)

J. Gedicke, A. Olowinsky, U. Jansen, W. Schulz, A. Gillner:
Weld depth control in fiber laser welding of thin metal sheets
Proc. of the 27th Int. Congress on Applications of Lasers & Electro-Optics 2008, ICALEO, Temecula, CA, USA, October 20-23, (2008)

S.Kaierle, M. Dahmen, S. Mann, R. Poprawe:
Autonomous Production Cell for Laser Beam Welding
Proc. Int. Conf. on Competitive Manufacturing "COMA 07", Stellenbosch, Südafrika, 6 S., (2007)

C. Franz, S. Mann, S. Kaierle:
Comparison of process monitoring strategies for laser transmission welding of plastics
Proc. of ICALEO 2007, Orlando, Fl. 602-606, (2007)

M. Dahmen, W. Fiedler, B. Regaard, S. Kaierle:
Continuous process control during laser beam welding of small section Aluminium sheet
Proc. of WLT Conf. Lasers in Manufacturing, Munich, 5 S., (2007)

B. Regaard, W. Fiedler, S. Kaierle:
Error detection in lap welding applications using on-line melt pool contour analysis by coaxial process monitoring with external illumination
Proc. of WLT Conf. Lasers in Manufacturing, Munich, 5 S., (2007)

W. Fiedler, M. Dahmen, S. Kaierle:
Process control of laser beam welded small section aluminum sheets
Proc. of ICALEO 2007, Orlando, Fl., 271-276, (2007)

J. Gedicke, B. Regaard, K. Klages, A. Olowinsky, S. Kaierle:
Comparison of different process monitoring methods for laser beam micro welding
Proceedings of ICALEO 2006, 8 S., (2006)

J. Gedicke, B. Regaard, A. Gillner, S. Kaierle:
Kontrolle beim Mikroschweißen - Automatisierte Prozessüberwachung durch koaxiale Prozesskontrolle mit Fremdbeleuchtung
Laser Technik Journal 3, 33-37, (2006)

B. Regaard, S. Kaierle, R. Poprawe:
Self guided laser welding
Proceedings of ICALEO 2006, 7 S., (2006)