en.Wedoany.com Reported - In the production of high-value components such as batteries, hairpin motors, and bipolar plates, the weld surface may appear perfect, yet internal defects like pores and cracks can exist, affecting yield rates. The intelligent process monitoring system launched by German company 4D Photonics, consisting of the 4D.TWO sensor and 4D.watcher software, aims to solve this problem by making the welding process internally transparent.

This laser welding system utilizes over 26 spectral channels, sampling more than 1 million times per second, and achieves dead-zone-free continuous monitoring through a patented lossless integration technique, capable of capturing anomalies within 20 microseconds. It also integrates temperature, humidity, air pressure, and a 9-axis motion tracker, providing complete process data. The system supports remote software configuration for rapid deployment.

During real-time monitoring, the system can identify defects such as cracks, pores, and spatter and issue alarms. It intelligently classifies fault types through multiple evaluation channels, reducing false defect rates. Data supports protocols like PLC and OPC-UA, facilitating integration into existing production lines. Typical applications include battery cell welding, hairpin motor welding, and fuel cell bipolar plate welding, all validated on actual production lines.

With 30 years of experience in laser monitoring, 4D Photonics has installed over 2,000 systems globally. The sensor is compatible with mainstream laser processing heads from companies like TRUMPF and IPG. This system provides a transparent monitoring solution for laser welding quality assurance, empowering industrial manufacturing.

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