AI-Enhanced Robotic Induction Brazing

This video demonstrates the capabilities and robustness of the UltraFlex' AI-Driven Dragon 24 induction brazing system, utilizing Universal Robots cobot. Equipped with a high-speed camera, the cobot initially scans and takes images of the entire heat exchanger. These images are then analyzed through our AI models to detect unbrazed U-Bends, brazed U-Bends, Empty Flanges and Brazing alloy rings. In addition to finding their positions and orientations, the AI can also detect both Copper and Aluminum U Bends. These AI models are trained through specialized data collection and augmentation, making them robust to changes in lighting conditions, color and scale of the parts, and rotation of camera images. Furthermore, each U-Bend's properties like dimensions, positions and orientations are tracked. The AI results are then used to command the robot to move the induction coil only to unbrazed U-Bends that are fitted with brazing alloy rings and avoid any badly fitted U-Bends to prevent brazing of wrongly loaded parts. You can notice here that the AI directs the robot to skip unbrazed U-Bends with missing brazing alloy rings and brazed U-Bends as well. This allows for preventing defects due to operator errors and enables heat exchanger configurations to have some already brazed U-Bends. Moreover, U-Bends that are too long for the induction coil or in crossover configurations are also skipped. Our configuration checking algorithm uses the AI results to graphically display any missing or misplaced U-Bends, missing brazing rings, and unexpected brazed/unbrazed U-Bends. This can be used by the operator to quickly rectify any faulty part loading, leading to better pre-braze quality control. This AI-powered solution revolutionizes manufacturing by providing precise detection and processing capabilities for U-Bends, adapting to variable conditions, and minimizing operator errors. Furthermore, this technology can be easily adapted to be used for a variety of HVAC assemblies, such as compressor or heat pump assemblies and components. It can be used with the UltraFlex brazing equipment or as a standalone QC monitoring system. Its real-time feedback and selective processing enhance efficiency and quality control, positioning it as a leader in industrial innovation.