Adaptive Control and Real-Time Sensing in Laser Welding for Industry 4.0: A Critical Review

Abstract

The current review involves the related application of the laser welding technologies to the Industry 4.0 model focusing on the functions of smart sensing, process automation, and adaptive control. The benefits of digital technologies, i.e., the Internet of Things (IoT), artificial intelligence (AI), and cyber-physical systems, attract more benefits with the development of laser welding. The innovations lead to enhanced accuracy, flexibility, efficiency and predictive maintenance, and real-time quality control. This paper provides a fast overview of how adaptive control systems make laser welding respond dynamically to sensor feedback in control of the quality of the delivered weld and morphology reduction in order to mitigate defects. As a part of better traceability, critical welding parameters, including temperature and depth of penetration and real-time corrective measures, are monitored with a smart sensor and processed into higher quality outcomes. Robots with articulation and collaborative robots (cobots) can complete routine and efficient work during the production cycle and make visions of harmless relations between humans and robots. The article reports actual use cases in the manufacturing sectors of automobile and aerospace industries, in which the new weld modalities with their novelty improve capacity and take relatively shorter time. Other problems that have been identified during the review are related to integration cross-boundary problems including system inter-operability, problems related to cyber security and the need to upskilling workforce. The application of digital twins and new AI-based welding tools and greenery take the sequel as the next trend. Overall, the document offers laser welding as an innovation in Industry 4.0 which will support manufacturing although it targets smart, data-driven, and sustainable manufacturing.