This information will be processed and rewired to a central control system, which will adapt the process parameters in real-time (i.e. laser power, focal position, feed rate). The implementation of the control unit will be based on a special developed process and control model with experimental and simulative support. A prototype of the complete adaptive laser transmission welding solution will be implemented on a laser transmission welding machine with the aim to validate the method. In this context, real demonstrator work pieces from important industrial applications like the medical and automotive fields will be defined by the project partners and used for the final proof of principal.
As a result the laser transmission welding process will improve its performance, stability, efficiency, accuracy and in special end product quality. Additionally, the possibility of a fast and automatic process initialization based on the combination of the simulation tool and the feedback control unit decreases the overall product time to market and the process non-productive time. Furthermore, it increases the precision of the process parameter set-up, thus increasing the overall production performance. The integrated measurement system will also allow the evaluation of the rest gap between the weld partners before the welding, leading to a direct control of the processes axial joining forces neccessary for a robust join. Moreover, the inline measurement system associated to an image processing unit will also be used to execute an in-situ non-destructive quality assurance of the weld seam. This application of the measurement system also leads to the possibility of a 100% process inspection, which is compliant with high demanding production chains (i.e. medical). Based on preliminary tests, the proposed solution will also be applicable to industrial fields, which are not covered by the state-of-the-art process monitoring and feedback control technologies as processes using plastic weld partners with thicknesses over 2 mm or with glass-reinforcement levels over 30% per weight as well as with material inhomogeneity.