audiLink

The “audiLink” project is dedicated to the development of an acoustic sensor array for location-independent process monitoring in remote laser welding.

Laser material processing has established itself in recent years as one of the most efficient and precise methods for processing materials, particularly in the automotive, electrical, and mechanical and plant engineering industries. These technologies are known for their high flexibility and precision, especially in remote laser welding, where the laser beam is moved dynamically while the component remains in a fixed position. This type of welding enables the processing of complex geometric shapes and is particularly relevant for the production of components with high value creation. However, companies face the challenge of reliably monitoring the quality of the weld seams to ensure that no critical defects occur that could jeopardize the integrity of the products. Traditional process monitoring methods, such as optical sensors, are often unable to effectively account for the dynamic changes that occur during remote welding, as they rely on direct visibility. This is leading to growing demand for innovative solutions that enable reliable process monitoring even under difficult conditions.

audiLink aims to develop an acoustic sensor array specifically designed for the requirements of remote laser welding. The focus is on developing a robust, location-independent system for acoustic process analysis that is capable of detecting critical process states and resulting seam defects in real time. The use of inexpensive airborne sound sensors and low-latency AI-based data processing enables dynamic adaptation to the constantly changing conditions during the welding process. The system should be able to identify typical seam defects and support automated process control to ensure the quality of the weld seams. A central aspect of the project is the integration of acoustic sensors into existing manufacturing systems so that companies do not have to replace their current equipment but can instead benefit from the advantages of this new technology by simply retrofitting it.

The results of the audiLink project have the potential to significantly increase the competitiveness of small and medium-sized enterprises (SMEs). The introduction of an acoustic monitoring system enables fast and precise inline process monitoring, which is particularly important for complex 2D and 3D laser welding applications. The ability to predict seam quality in real time and monitor the condition of the equipment is crucial for minimizing scrap and production costs. In addition, the flexibility and adaptability of the system will enable companies to respond better to market requirements and produce innovative products more efficiently. The technologies developed within the project could also be extended to other laser material processing applications, further increasing the benefits of the research results.

“audiLink” is a joint project with the Fraunhofer Institute for Machine Tools and Forming Technology IWU.