Object detection vision sensor VisionLine

for defect detectionHMI

Overview
TRUMPF VisionLine is a camera-based image processing system for cutting and welding applications. VisionLine automatically detects component position, forwards measurement data to the machine control and supports correct seam or focus placement. It is available as an integrator package for laser optics as well as for TruLaser Station and TruLaser Cell systems.

Key features

• Camera-based position detection and visual observation with focus cross-hair.
• Predefined attribute/template library for teach-in and rapid task creation.
• Options: Basic (workpiece monitoring), Detect (edge/feature recognition), Project (customer-specific implementations); Adjust available for TruLaser Cell 3000.
• Compatibility with TruDiode, TruDisk, TruFiber and TruPulse laser sources.

Benefits

• Improved process capability: reduces component positioning constraints without loss of quality.
• Faster integration: intuitive UI and attribute library simplify setup and commissioning.
• Traceability: image data can be stored for process documentation and quality control.
• Single-source integration: TRUMPF supplies laser, process sensor system and application consulting.

Product variants

• VisionLine Basic: digital camera image with cross-hair in the laser focus for monitoring and teach-in; corrects observation/laser offset especially with PFO scanner optics.
• VisionLine Detect: edge detection and template-based feature recognition (spots, circles, lines, intersections) to support position correction.
• VisionLine Project: customer-specific service package including feasibility study, development of process-stable image processing routines and documentation.

AI & training
VisionLine Detect can be extended with EasyModel AI, a cloud-based training platform that enables image-based AI model training with limited data and no programming knowledge. The VisionLine Detect AI filter improves feature recognition under challenging lighting or variable upstream processes.

Applications

• Hairpin welding in motor stators (precise hairpin position recognition).
• Welding of electronic components: detection of pins in control units, sensors and actuators.
• Welding of joint connections: detection of seam points in heat exchangers or seat rails.
• Marking and distance measurement for quality control on gearbox and other parts.

Technical specifications

• Available systems: TruLaser Cell 3000 (integrable with TruLaser Station and other laser systems).
• Compatible lasers: TruDiode, TruDisk, TruFiber, TruPulse.
• Options: Basic, Detect, Project; Adjust (TruLaser Cell 3000).
• Available focal lengths (examples): 150 / 200 mm (FocusLine Professional); 150 / 200 / 250 mm (WeldLine Modular); 150 / 200 / 250 / 300 mm (BEO D50); 200 / 300 mm (BEO D70); 255 / 345 / 450 mm (PFO 33-2); 255 / 450 mm (PFO 3D-2).
• Typical image processing time: 80 ms - 150 ms.
• Typical working-distance search precision: ±50 μm (f = 150 mm, TruLaser Cell 3000).
• Typical position recognition precision: ±20 μm in the image centre.