3D Weld Inspection System

A-Tech brings you Coretec’s 3D Weld Inspection System, an innovative, patented solution that fully automates your weld inspections. Combining 3D camera technology and robotics, it ensures fast, precise results for a wide range of weld types.

Weld Inspection Just Got Smarter

Inspections no longer need to be a bottleneck. With automation transforming the industry, POLASTAR takes weld quality control to the next level.

POLASTAR is the brand name of CORETEC’s 3D inspection system.

From Visual Inspection to Automation

Don’t waste time with slow manual inspections when a faster, smarter, and fully automated solution exists!

Patented Innovation: No Need for Scan Direction

What truly sets Coretec’s system apart is its patented cross-sectional analysis method. Traditional systems require the robot to follow precise scan directions, often leading to time-consuming setups and limited inspection angles. Coretec’s innovation changes the game. By analyzing the weld after capturing its 3D shape and drawing a judge line, the system allows the robot to inspect without any predefined scan paths. This leads to faster cycle times, simplified programming, and fewer operational headaches.

Less time wasted, more production gained

Below, you’ll see an example of a traditional weld inspection system. Notice how the camera must align with the weld’s route lines to ensure accurate inspection, complicating the process—especially with curved or spiral welds. These limitations can distort the 3D shape and extend the scan time.

In contrast, Coretec’s system captures the true 3D shape first and then applies a judge line. This flexible approach means the system can perform accurate inspections without needing precise robot alignment or teaching, ensuring faster and more reliable results. The 3D shape generated mirrors the actual weld, offering clarity and confidence in every inspection.

Fast, precise, and reliable in every weld. Turnkey solution for future weld inspection.

Real-Time 3D Shape Capture

In industrial environments, changes in robot movement or positioning can impact the inspection process. Coretec’s system overcomes this by continuously tracking the robot’s coordinates in real-time, ensuring consistent and accurate 3D shapes, even when the robot’s posture shifts. No detail is missed, whether you're working with intricate welds or fast-paced production lines.

If a single scan can’t capture the entire weld due to physical obstructions, the system automatically breaks the process into multiple scans. These scans are then seamlessly combined to create a complete and accurate 3D model of the weld.

Looking Closer at POLASTAR

At the heart of Coretec’s 3D Weld Inspection System is the perfect pairing of a robot and advanced 3D camera, working together to fully automate the inspection process. Each weld is scanned and analyzed in just 1.5 seconds, performing both tasks simultaneously for unmatched efficiency.

How it works?

The system scans the weld using a 3D camera and gathers coordinate data from the robot.
An accurate 3D shape is then created by combining the scanned data with the robot’s position information.
Once the 3D shape is generated, a judge line is drawn, allowing the system to analyze specific sections.
Welds are evaluated based on absolute dimensions, ensuring precise and consistent pass/fail results.

Smarter, Faster Setup

Setting up robotic paths can often slow down automated inspections. Coretec’s system simplifies this process with its laser guide feature, significantly reducing the time needed for teaching. The robot no longer requires complex movements or fine-tuned adjustments. Just guide, program, and let the system do the rest—allowing you to focus more on production and less on setup.

Easy Robot Integration

Integrating the system into an existing production line is simple. Coretec’s system is compatible with major robot manufacturers, offering seamless data sharing across platforms.

Have idle robots? Put them to work. Coretec’s solution allows you to maximize your equipment without the need for additional capital investments, making it a cost-effective choice for any production line.

Two Configurations to Match Your Needs
We offer two configuration options for Coretec’s 3D Weld Inspection System: Standard and Compact.

Standard Configuration: Designed for full integration into production lines, it communicates with the equipment’s PLC and ensures real-time inspection data is available throughout the process.
Compact Configuration: A standalone option with simplified functionality, ideal for demonstration purposes or as a pre-production solution before full integration.

Applications

Ideal for industries like automotive, heavy machinery, and railcars, the Coretec 3D Weld Inspection System offers a complete, turnkey solution for high-volume production lines. With automated precision and patented technology, you’re not just inspecting welds; you’re improving your entire process.

Tailored for Every Weld Type

No matter the welding method, Coretec’s 3D Weld Inspection System adapts effortlessly to ensure precision across all applications, from arc welding to laser welding and tailored blanks. Versatility meets performance with this system.

Arc Welding: Packed with over 30 inspection checkpoints, including weld length, leg lengths, and bead position, this system makes sure each arc weld is flawless.
Laser Welding: Precision is key with zero bead height applications, and Coretec’s system guarantees perfect results with laser welds, ensuring nothing is left to chance.
Tailored Blanks: For long welds, the system uses dual-camera scanning, inspecting both the front and rear simultaneously. Full coverage, zero defects.

Custom Features and Built-In Traceability

Coretec’s 3D Weld Inspection System is designed to give you full control over your inspection process while ensuring complete traceability.

Fully Selectable Functions: With customizable parameters, the system allows users to freely choose the inspection criteria that match their needs, ensuring precision for every weld.
Seamless Traceability: All 3D shape data is saved and easily exported as CSV files, providing you with the ability to track and document every inspection for quality assurance.
Easy-to-Use Interface: The user-friendly screen makes navigation and adjustments effortless, giving you full control over the inspection process with minimal hassle.

3D Camera Head

Coretec’s 3D camera comes in two configurations: Standard Type and Long-Distance Type. Each is designed for specific inspection needs, offering flexibility in use and installation. Below is a detailed diagram of the 3D camera head dimensions for both configurations, showcasing the system’s adaptability to various inspection scenarios.