CONSULTING

GUIDE
For the Welding Industry

Proposal of a Truly Workable Measurement System

for Welding Processes
 Applications for Welding Processes

Pre-welding Application Groove Control

Requirement for measurement

To improve welding accuracy by providing measurement of the groove position of the base material to the welder as feedback.

Welder

Base material

Issues

Conventional method

1 Multiple contact sensors are required.

2 Multiple reflective laser displacement sensors are required.

Issues with the conventional method

1 Sensors cause scratches on the inspection object; Long cycle time

2 Limited installation space; Measurement points shift due to the target
shifting position

After introducing the LJ-V Series

With the line sensor head, one head covers a large area of measurement. Even when displacement of
the inspection object occurs, the position is adjusted to ensure correct measurement points.

Angle

Intersection
position
(X and Z
coordinates)

2
Post-welding Application Weld Bead Profile Analysis

Requirement for measurement

To perform 100% inspection after welding to check the weld bead profile and penetration, as well as check for undercutting.

Master shape

Measurement value

Issues

Conventional method

1 Visual inspection
2 Image sensor

Issues with the conventional method

1 Increased man-hours spent on inspection; Concerns for targets escaping

inspection due to human error
2 False detection due to color irregularity

After introducing the LJ-V Series

In-line automatic 100% inspection is achieved by driving the sensor unit so that it follows the welder torch.
False detection resulting from color irregularity is eliminated by using the profile instead of appearance to detect
welding defects.

Welding
defect
detected!

3
 KEYENCE TECHNOLOGY for Welding Applications

Outstanding Responsiveness and Ultimate Stable Detection

Typically, laser displacement sensors need an optimal amount of reflected light in order to obtain a stable profile. Because
the adjustment is made to the light received from the target as a whole, a difference in reflected light occurs when measuring
curved surfaces or surfaces with different colors. For this reason, in cases where the dynamic range of the CMOS element
(light receiving element) is small, the correct profile cannot be obtained, as shown below.

Optimizing the light reflected by a planar part Optimizing the light reflected by an oblique part

形状データ
Profile data Profile data

Insufficient light received from Too much light received from

oblique and darker parts parts close to flat

Simultaneous processing of light reflected off a large area is required for accurate measurement of curved surfaces or
composite materials, which translates to a need for light receiving elements that have a broader dynamic range.

After introducing the LJ-V Series

The HSE3-CMOS adopted in the LJ-V Series offers an
outstanding dynamic range of 2400 times the average CMOS.

One system supports ever y measurement

Introducing 74 measurement modes
One LJ-V Series system supports a total of 74 measurement modes with 16 types of measurement settings and 11 types of
target specifications.

ANGLE AND MASTER PROFILE

HEIGHT WIDTH AND POSITION INTERSECTION COMPARISON

Peak Knee
Master shape
Angle
Average
Intersection
position Measurement
(X and Z value
Bottom Width coordinates)
Measures the height within the specified Measures the width and positions under Measures the angle between and the intersection Makes a comparison with the registered
range. the specified conditions. point of a pair of detected straight lines. master shape and then measures the area
with the largest difference in height.

CROSS SECTIONAL DISTANCE RADIUS AND

HEIGHT DIFFERENCE AREA (POINT - POINT) MIDPOINT
Measurement Distance
point Cross sectional (X and Y) Measurement value
Peak
area
Knee
Height difference

Reference surface
Reference point Reference surface

Measures the height difference from a Measures the cross sectional area from Measures the distance between two points. Measures the radius of a curved profile and the
reference point to a measurement point. a reference surface. coordinates of the center position of a specified point.

4
Advantages of Blue Laser
While red light is most common for laser displacement sensors, a blue laser, which was expected to bring many advantages,
is now being adopted in laser displacement sensors since stable laser performance has been established. The blue laser has
a wavelength of 405 nm, which is approximately 1.5 times shorter than red lasers, which have a wavelength of 650 nm.
The following details the working principle of blue-laser displacement sensors and situations where their characteristics make
them useful due to this difference in wavelength.

When measurement speed is insufficient

For laser displacement sensors, the light receiving density must be raised in order to ensure appropriate received light over
the short exposure time.

CASE 1 Comparison of 2D laser displacement sensors of

the same type 48 mm 1.89"
Light source Red laser Blue laser 200 mm 48 mm
Model LJ-G200 LJ-V7200 7.87" 1.89"
106 mm
4.17"
Spot width ➊ 180 μm 0.007087” 85 μm 0.003543” 90 mm 310 µm
3.54" 2 0.012205"
Spot width ➋ 380 μm 0.014961” 310 μm 0.012205” 1 85 µm
74 mm 0.003543"
2.91" 310 µm
2
0.012205"
Light intensity
Red laser Blue laser

Laser spot diameter

Because the received-light wave pattern will have a higher peak with a smaller spot width during the same exposure time,
the LJ-V Series provides stable measurements with a shorter exposure time.

 lue-laser displacement sensors can provide stable measurements

B
even with high-speed sampling

When ambient light is present

A red-laser displacement sensor has a band-pass filter

that only passes light with wavelengths close to 650 nm
attached to the front of the light-receiving unit. However, Band-pass filter that only lets
radiated light from a red-hot steel plate or similar through light close to 405 nm
products mostly has wavelength components in the red
to infrared spectrum, which means that the light in this
part of the spectrum passes through the band-pass filter, Light radiated from
resulting in ambient light affecting the measurement. high-temperature target
However, a blue-laser displacement sensor uses
(largely contains red light component)
a band-pass filter that only passes light with wavelengths
close to 405 nm and shuts out red to infrared wavelength
components, which enables measurement without being
affected by ambient light.

 lue-laser displacement sensors are unaffected by radiated light

B
from red-hot steel plates

5
 System Overview

Sensor Head Lineup

Ultra high-accuracy
Ultra high-accuracy specular reflection High-accuracy High-accuracy specular reflection

LJ-V7020 LJ-V7020K LJ-V7060 LJ-V7060K

(mm)
(inch)

450
17.72"

400
15.75"

350
13.78"

300
11.81"

250
9.84" Measurement
Measurement range
200
Measurement range 54.6 ±7.6 mm
7.87"
60 ±8 mm
Measurement range 2.15"±0.30"
2.36"±0.31"
150
5.91"
range 24.2 ±2.3 mm
20 ±2.6 mm 0.95"±0.09"
100 0.79"±0.1"
3.94"

50
1.97" 52 mm 2.05" 47 mm
17.4 mm Width: 13.5 mm 0.53" 1.85" Width: 8 mm 0.31"
0.69" Width: 6.5 mm 0.26" 21.9 mm 0.86" Width: 6.5 mm 0.26"
20 mm 24.2 mm 0.95" 60 mm 2.36" 54.6 mm Width: 14 mm 0.55"
0 Width: 7 mm 0.28" Width: 7 mm 0.28" Width: 15 mm 0.59" 2.15"
0.79" 26.5 mm 1.04" Width: 8 mm 0.31"
22.6 mm Width: 7.5 mm 0.30" Width: 7.5 mm 0.30" 68 mm 2.68" Width: 15 mm 0.59" 62.2 mm
0.89" 2.45"
Measurement Z-axis 20 ±2.6 mm 0.79"±0.1" Measurement Z-axis 24.2 ±2.3 mm 0.95"±0.09" Measurement Z-axis 60 ±8 mm 2.36"±0.31" Measurement Z-axis 54.6 ±7.6 mm 2.15"±0.30"
range range range range
X-axis 7 mm 0.28" X-axis 7 mm 0.28" X-axis 15 mm 0.59" X-axis 14 mm 0.55"
Z-axis 0.2 µm 0.000008" Z-axis 0.2 µm 0.000008" Z-axis 0.4 µm 0.000016" Z-axis 0.4 µm 0.000016"
Repeatability Repeatability Repeatability Repeatability
X-axis 2.5 µm 0.000099" X-axis 2.5 µm 0.000099" X-axis 5 µm 0.000197" X-axis 5 µm 0.000197"

Middle range Long range Ultra-long range

(mm)
LJ-V7080 LJ-V7200 LJ-V7300
(inch)

450
17.72" Measurement
range
400
15.75"
Measurement 300 ±145 mm
range 11.81"±5.71"
350 200 ±48 mm
13.78" 7.87"±1.89"
300 155 mm Width: 110 mm
11.81" 6.10" 4.33"

250
9.84" Measurement
range
200 80 ±23 mm
7.87"
3.15"±0.91"
150 300 mm 11.81"
5.91"
Width: 180 mm
100 152 mm 5.98" 7.09"
3.94" Width: 51 mm 2.01"

57 mm 2.24" Width: 25 mm 0.98"

50 200 mm 7.87"
1.97"
80 mm 3.15" Width: 62 mm 2.44"
Width: 32 mm 1.26"
0
103 mm 4.06" Width: 39 mm 1.54" 248 mm 9.76" Width: 73 mm 2.87" 445 mm 17.52"
Width: 240 mm
9.45"
Measurement Z-axis 80 ±23 mm 3.15"±0.91" Measurement Z-axis 200 ±48 mm 7.87"±1.89" Measurement Z-axis 300 ±145 mm 11.81"±5.71"
range range range
X-axis 32 mm 1.26" X-axis 62 mm 2.44" X-axis 180 mm 7.09"
Z-axis 0.5 µm 0.000020" Z-axis 1 µm 0.000040" Z-axis 5 µm 0.000197"
Repeatability Repeatability Repeatability
X-axis 10 µm 0.000394" X-axis 20 µm 0.000788" X-axis 60 µm 0.002363"
6
Using the LJ-V Series with 2D measurements

LJ-V System Configuration

Sensor/trigger Sensor
head Sends the measured
Display  Communication
values to the welder
Controller

(3 or 10 m 9.8' or 32.8')
output unit unit PC as feedback

Connection cable
Encoder

I/O
PLC
Analog voltage EtherNet/IPTM
PROFINET
RS232C

Ethernet

PLC PC Console RGB Monitor Touch panel HMI

Using the LJ-V Series with 3D measurements

The addition of an image processing controller enables

data accumulation of cross-sectional data for image
analysis based on the 3D profile.

Weld sample with holes

Scan the 3D profile...

Image processing and analysis

7
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