Inline Weld Watching: State-of-the-art technology for the highest welding quality

Quality assurance is a key factor in modern production. Monitoring the welding process plays a crucial role, especially in laser welding, where the requirements for precision and safety are immensely high. One of the most innovative technologies in this field is Inline Weld Watching. But what exactly is behind this process and how does it support quality assurance? You can find out this and more in this blog.

What is Inline Weld Watching?

When it comes to the quality control of weld seams, the term “inline weld inspection” is often used. This is the inspection process that only takes place after the welding process has been completed. Inline Weld Watching, on the other hand, starts one step earlier. Here, the ongoing welding process is monitored in real time.

In this process, spectrographic sensors analyse the reflection of the hot plasma in certain frequency ranges. This method makes it possible to recognise errors or deviations immediately and initiate the appropriate measures even before the workpiece has cooled down.

Inline Weld Watching also offers another key unique selling point: quality control during series production. Specific tolerance bands are defined for each individual seam. The software continuously compares the measured values with these specifications and assesses the quality in real time.

The advantages of Inline Weld Watching

In Rejlek’s automated systems, inline weld watching technology ensures that faulty components are automatically sorted out. This means that only flawless goods reach the customer – an indispensable advantage, especially for safety-relevant components in the automotive, aviation or energy technology sectors.

Another advantage is the ability to use the collected data for process optimisation. This feedback loop allows welding parameters to be fine-tuned in order to make future production cycles even more efficient and precise.

In addition to the guaranteed quality of the end products, inline weld watching also offers advantages in terms of costs and sustainability. Defects are detected at an early stage, avoiding expensive reworking or rejects, and the efficient use of resources minimises waste and reduces the environmental impact.

Measurable parameters: A look at the details

The centrepiece of Inline Weld Watching at Rejlek are highly developed spectrographic sensors. These measure the strength of the plasma light in a frequency range typical for the welding process. The sensors work in real time with specially developed software that immediately compares the measurement results with defined standards.

This method can be used to evaluate key quality features, including

• Seam length: A uniform seam length is crucial for the stability and functionality of the assemblies.
• Seam quality: Potential defects or inclusions that could impair the load-bearing capacity are recognised here.
• Connection: Inadequate connections, for example due to excessive gap dimensions, are identified and documented.

Thanks to this comprehensive monitoring, Rejlek can fulfil even complex requirements and ensure that the products function reliably even under extreme loads.

Application in safety-critical components

The products manufactured by Rejlek are used in demanding and often safety-relevant areas. Two examples of this are

• Brackets for steering columns: These carbon steel assemblies must meet the highest safety requirements as they are directly integrated into the vehicle’s control system.
• Busbars for batteries: These aluminium components are essential for energy transmission in modern electromobility applications.

In both cases, the weld seam plays a decisive role, as it contributes significantly to the stability and function of the components. Inline Weld Watching ensures that this seam meets the highest standards.

Expertise as the key to success

Although the systems used are available on the open market, Rejlek is characterised by its comprehensive expertise, which is developed and continuously refined in-house. The testing processes are individually customised for each product.

This is particularly important because there are no official standards for inline weld watching. Instead, the efficiency of this technology depends heavily on technical expertise and the ability to optimally adapt the systems to specific requirements. This is where Rejlek sets new standards with its experienced technicians and engineers.

Conclusion: Achieving the highest quality in real time

Inline Weld Watching is a pioneering technology that helps companies like Rejlek meet and exceed their quality standards. With the ability to monitor welding processes in real time and identify defects immediately, this process offers enormous advantages in production.

Thanks to inline weld watching technology, we at Rejlek guarantee the highest precision and quality for your products. Contact us now to find out more about our customised solutions.