A new AI-powered laser repair system for mining equipment is being developed through an international collaboration led by Fraunhofer ILT. The project, known as AI-SLAM (Artificial Intelligence Enhancement of Process Sensing for Adaptive Laser Additive Manufacturing), aims to automate the repair process for worn mining tools that would typically be discarded and replaced.
Mining tools like this excavator bucket tooth are subject to extreme wear. Ultra-accurate AI-assisted laser material deposition is used to perform repairs quickly and cost-effectively right on the machine. (Image Credit: Fraunhofer ILT)<br />
The system uses laser material deposition (LMD) technology to restore damaged mining equipment by applying precise metal coatings. During the repair process, stainless steel is melted at approximately 1300°C while tungsten carbide particles are simultaneously deposited, creating a durable protective layer that resists both wear and corrosion.
The AI component manages 150 different parameters during the repair process, handling everything from initial damage assessment to final quality control. A CMOS camera with line laser scanning captures the worn tool’s surface geometry, which is then compared to the original specifications to determine the precise coating requirements.
The project brings together expertise from multiple organizations, including Canada’s National Research Council, McGill University, and technology firms Braintoy and BCT. “All the human operator needs to do is push the start button,” explains Max Zimmermann, project manager at Fraunhofer ILT’s Laser Material Deposition department.
The technology addresses several technical challenges, including maintaining the optimal ratio of tungsten carbide to steel and precise temperature control to prevent tungsten carbide from melting at its 2900°C threshold. The system’s AI monitors the entire process through camera feeds, detecting and responding to any irregularities during operation.
The AI-SLAM project will be demonstrated at the upcoming Hannover Messe Preview on February 19, 2025, with a software demonstration available at the main Hannover Messe event from March 31 to April 4, 2025, at the Fraunhofer booth in Hall 2.
Source: fraunhofer.de
