Product Category: Software & Control Systems

Sigma Laser Welding Software – Overview & Best Practices

Sigma Laser’s welding software is a high-precision control solution designed to operate and manage laser welding systems with efficiency, traceability, and automation readiness. It serves industries requiring precise material joining, such as electronics, medical devices, battery packs, and automotive components.

Core Features

1. User Interface & Operation

• Intuitive, touchscreen-enabled UI
• Visual programming of weld paths
• Real-time feedback for operators
• Quick-access toolbar for commonly used functions

2. Parameter Control

• Adjustable parameters: laser power, frequency, pulse width, focus
• Save/load job files and parameter sets
• Compatible with different laser types (fiber, pulsed, CW)

3. Monitoring & Diagnostics

• Real-time process monitoring (temperature, position, error status)
• Alerts and interlocks for safety and system protection
• Diagnostic logs for troubleshooting

4. Integration & Communication

• Connectivity with external systems (PLC, MES, ERP)
• Interfaces: USB, Ethernet, or RS-232
• Optional API for third-party automation systems

5. Automation & Robotics Compatibility

• Supports CNC tables, gantry systems, and robotic arms
• Sequencing tools for automated workflows
• Step-by-step execution or continuous operation mode

6. Documentation & Traceability

• Automatic logging of welding parameters per job
• Export options for CSV, PDF, or database systems
• Supports ISO-compliant quality documentation

Best Practices

1. Interface & Usability

• Design UI for minimal operator training
• Enable multilanguage support for international teams
• Use visual aids like 2D/3D path previews and heat maps

2. Parameter Libraries

• Build and maintain a library of material-specific welding recipes
• Tag each entry with use cases (e.g., aluminum 0.3mm tab, steel enclosure weld)

3. Sensor-Based Closed-Loop Control

• Integrate seam tracking cameras, pyrometers, or laser displacement sensors
• Enable auto-adjustment of laser parameters based on sensor feedback

4. Traceability & Logging

• Log all operational data for each weld (time, energy, operator, etc.)
• Archive and retrieve logs for auditing or optimization

5. Cybersecurity

• Role-based access control (RBAC) for different user levels
• Protect configuration and firmware with encryption and secure login

6. Remote Management

• Enable remote diagnostics and firmware updates
• Offer cloud connectivity or secure VPN access for offsite monitoring

7. Modularity

• Allow scalable upgrades (e.g., from semi-auto to full-automation)
• Use a plugin architecture for additional capabilities like AI defect detection

Future-Forward Capabilities (Optional Add-ons)

Sigma Laser Welding Software Suite

Including SIGOMATIC – Smart Process Control System

Introduction

Sigma Laser’s software ecosystem is engineered to deliver precise, efficient, and intelligent laser welding operations. The system’s backbone is its core welding software, while SIGOMATIC serves as a cutting-edge module for real-time quality control and smart welding feedback. Together, they form a robust platform for mission-critical applications in medical devices, battery systems, automotive, aerospace, and microelectronics.

Overview of SIGOMATIC

SIGOMATIC is Sigma Laser’s proprietary quality monitoring and feedback system for laser welding. It enables inline weld inspection and closed-loop control by analyzing optical process signals (such as reflected light intensity or emissions) and reacting in real time.

Key Objectives:

• Ensure weld quality consistency
• Minimize defective parts and rework
• Enable predictive error detection
• Comply with high-regulation industry standards

Core SIGOMATIC Features

1. Inline Process Monitoring

• Real-time capture of light intensity emitted during each weld pulse
• Non-destructive weld inspection with no need for external sensors
• Applicable for highly reflective materials (e.g., copper, aluminum)

2. Signal Evaluation

• Pulse-by-pulse signal recording
• Analysis of deviations from reference patterns (ideal weld)
• Configurable tolerance ranges for pass/fail evaluation

3. Automatic Fault Detection

• Auto-stop or alert on signal deviation
• Flagging of suspect welds for post-process review
• Built-in logic for classifying faults (e.g., misfires, incomplete welds)

4. Traceability and Documentation

• Every weld gets a unique ID, timestamp, and status (pass/fail)
• Log files can be stored locally or sent to MES/ERP systems
• Export options for quality audits: PDF, CSV, database API

5. Closed-Loop Control (Advanced Option)

• Dynamic parameter adjustment based on feedback signal
• Adaptive control of laser power, duration, or pulse frequency
• Seamless integration with automation workflows

How SIGOMATIC Works

1. Reference Weld Setup
   An ideal weld is recorded to generate a “reference signal curve.”
2. Live Monitoring
   During operation, SIGOMATIC captures each pulse and compares it with the reference.
3. Deviation Analysis
   Signal amplitude, frequency, and shape are checked within set tolerances.
4. Result Action
   Depending on outcome:
   • ✅ Pass → Continue process
   • ⚠️ Warning → Mark for review
   • ❌ Fail → Trigger stop or flag defective part

Best Practices for Using SIGOMATIC

1. Set Clean Reference Signals

• Use high-quality, consistent sample welds to create a reliable reference profile.
• Avoid noise or signal artifacts during reference capture.

2. Optimize Tolerances

• Define narrow but realistic deviation thresholds to reduce false positives.
• Calibrate tolerances for different material thicknesses and geometries.

3. Use Signal Libraries

• Maintain a signal profile library for different product types
• Label them based on materials, laser settings, and part numbers

4. Enable Smart Logging

• Integrate with factory data systems to log weld evaluations in real time
• Attach log files to part serial numbers or barcodes

5. Train Operators on Signal Behavior

• Educate technicians to interpret signal trends and recognize common anomalies
• Provide access to sample signal waveforms for each defect type

Benefits of Integrating SIGOMATIC

SIGOMATIC vs. Traditional Weld Monitoring

Integration Architecture

SIGOMATIC can be integrated into:

• Sigma Laser’s standard software interface (as an additional module)
• Robotic cells or semi-automated welding stations
• MES / SCADA systems via API or Ethernet

Documentation & Standards

• Traceability: ISO 9001, ISO 13485, IATF 16949
• Weld Quality: ISO 13919-1 (Laser Weld Imperfection Tolerances)
• Data Management: Compatible with FDA 21 CFR Part 11 (for medical)

Summary

SIGOMATIC transforms Sigma Laser’s welding system into an intelligent, closed-loop platform. By monitoring and analyzing optical process signals in real time, it dramatically improves welding accuracy, reliability, and regulatory readiness.

Whether you’re building EV battery packs or precision medical implants, SIGOMATIC ensures that every weld is traceable, inspectable, and high-quality—without interrupting production.

Excellent choice. Sigomatic Pro is Sigma Laser’s advanced software for intelligent automation in laser welding systems. Below is a comprehensive Wiki-style documentation expanding your current software knowledge base to include Sigomatic Pro — structured, scalable, and optimized for engineers, integrators, or industrial clients.

Sigomatic Pro – Advanced Laser Welding Software

Introduction

Sigomatic Pro is the flagship laser welding control software developed by Sigma Laser GmbH. It is purpose-built for high-precision industrial applications requiring advanced automation, traceability, and flexibility. Sigomatic Pro acts as the central brain of Sigma Laser welding systems — offering powerful features such as smart programming, job tracking, and seamless integration with robots and external systems.

Key Capabilities

1. Advanced Motion Control

• Full control of multi-axis CNC and robotic systems
• Precise coordination of positioning tables (X/Y/Z) and rotation axes
• Supports servo motors, gantry systems, and industrial robotics

2. Smart Job Management

• Graphical programming of welding paths and sequences
• Import of CAD, DXF, or CSV job files
• Job queue and batch production modes

3. Intelligent User Interface

• Clean touchscreen-friendly design with status indicators
• Contextual UI adapts based on job or hardware setup
• Customizable dashboards and quick-access controls

4. Welding Process Optimization

• Real-time adjustment of laser parameters during execution
• Supports dynamic pulse width, power, and pattern modulation
• Integrated weld path smoothing and correction tools

5. Comprehensive Data Logging & Traceability

• Tracks operator, machine ID, job ID, material specs, and timestamps
• Export logs to Excel, CSV, or QMS databases
• Barcode/QR code-based job recall and part tracking

6. Full Automation & Robotics Integration

• Seamless connection to robotic arms (KUKA, FANUC, Yaskawa, etc.)
• Supports external signal triggering and I/O logic
• Camera-guided positioning and seam detection options

Best Practices for Using Sigomatic Pro

1. Project Setup & Recipe Management

• Use CAD import for accurate geometries
• Store recipes in grouped folders based on material and job type
• Use versioning control for parameter tuning

2. Parameter Fine-Tuning

• Record and analyze welding heat profiles with onboard sensors
• Utilize “trial run” modes to simulate toolpaths without active laser
• Validate energy input per mm based on material conductivity

3. Sensor Fusion & Adaptive Welding

• Combine vision sensors, seam tracking, and thermal imaging
• Enable closed-loop control based on reflectivity or gap detection
• Automate weld corrections in real time

4. Automation Workflow Design

• Script job sequences: clamp → align → weld → verify → unload
• Use PLC handshake signals for safe and synchronized motion
• Implement buffer queues for uninterrupted production

5. Security & Access Control

• Multi-user login with hierarchical privileges (operator, QA, admin)
• Track all changes to settings, recipes, and logs
• Enable auto-logout for idle systems to prevent tampering

6. Maintenance & Diagnostics

• Built-in maintenance schedules and system health monitoring
• Diagnostic pages for motor status, IO testing, and laser activity
• Automatic alert system for consumables, cooling, and interlocks

Competitive Advantages

Sample Workflow Diagram (Descriptive)

[ Start Job ]

↓

[ Load Workpiece ]

↓

[ Positioning System Aligns ]

↓

[ Vision System Locates Weld Path ]

↓

[ Laser Welding Begins ]

↓

[ Real-Time Monitoring Adjusts Parameters ]

↓

[ Weld Completion & Quality Check ]

↓

[ Save Log & Report ]

↓

[ Next Job / Repeat ]

System Requirements

Notes

• Sigomatic Pro is modular – designed to be scalable for small batch manual systems or full industrial automation lines.
• Software customization is available – integrators can request custom modules, multi-camera support, or vertical industry features (e.g., EV battery welding, jewelry, sensors, etc.)

Here’s an expanded Wiki-style knowledge entry on Remote Diagnosis based on the content at Sigma Laser – Remote Diagnosis and best practices in industrial laser service systems.

Remote Diagnosis – Sigma Laser Welding Systems

Introduction

Remote Diagnosis is a core module in Sigma Laser’s software ecosystem, designed to provide real-time remote support, error analysis, and system troubleshooting for laser welding systems. This capability enhances uptime, reduces maintenance costs, and ensures that both integrators and end-users receive fast and efficient support from Sigma Laser’s service team — regardless of geographic location.

Key Features of Remote Diagnosis

1. Live Remote Access

• Secure, real-time access to the laser system by Sigma Laser technicians
• Requires internet connectivity via Ethernet or Wi-Fi
• Allows live screen sharing, parameter inspection, and log access

2. Error Detection & Analysis

• Remote review of diagnostic logs and machine events
• Analysis of system warnings, fault codes, or welding inconsistencies
• Root cause analysis based on system status and sensor feedback

3. Firmware Updates & Configuration

• Push firmware upgrades remotely
• Adjust system configurations and default welding parameters
• Restore factory settings if required

4. System Health Monitoring

• Real-time check of component status: cooling, optics, sensors, motion systems
• Preventive maintenance suggestions
• Status visualization via online dashboards

5. Secure Connectivity

• Encrypted VPN or remote desktop tools (e.g., TeamViewer/AnyDesk)
• Access is only granted with customer permission and password
• Complies with GDPR and industrial cybersecurity best practices

Security Protocols

Best Practices for Using Remote Diagnosis

Preparation by the Customer

• Ensure the system is connected to the internet via a stable network
• Verify access rights and schedule support sessions in advance
• Maintain logs and screenshots for any irregularities before contacting support

During the Diagnosis Session

• Keep an operator or technician present at the machine for manual confirmation
• Allow screen/control sharing only during active support
• Monitor and log changes made remotely for internal records

Post-Support Process

• Receive a remote support report summarizing actions taken
• Update internal service logs based on resolved issues
• Apply preventive recommendations provided by the Sigma Laser team

Remote Diagnosis Use Cases

Benefits of Remote Diagnosis

• Faster Problem Resolution: Cuts downtime from days to hours
• Cost Efficiency: Eliminates or reduces on-site service visits
• Global Support: Access expert help from Sigma Laser regardless of time zone
• Continuous Improvement: Data collected helps improve future software versions

Super Pulse Technology (SPT) – Sigma Laser

Overview

Super Pulse Technology (SPT) by Sigma Laser represents a significant innovation in laser welding performance. It enables the generation of ultra-high peak power pulses within microsecond durations, resulting in cleaner, deeper, and more precise welds—especially in challenging materials such as copper, aluminum, and reflective metals.

This advanced pulsing technique enhances penetration, reduces spatter, and improves metallurgical bonding, particularly in high-reflective and conductive materials commonly used in industries such as battery production, electronics, and aerospace.

Key Technical Characteristics

Functional Benefits of SPT

1. Superior Weld Quality

• Deep fusion with minimal porosity or microcracks
• High strength-to-weight welds in thin materials
• Excellent surface finish with little or no rework required

2. Advanced Material Handling

• Welds high-reflective materials like copper (e.g., in EV battery tabs)
• Maintains thermal control even in heat-sensitive components

3. Low Spatter Operation

• Highly controlled pulse shapes eliminate metal ejection
• Essential for clean-room and precision manufacturing environments

4. Reduced Heat-Affected Zone (HAZ)

• Minimal thermal load on surrounding material
• Prevents deformation in microcomponents or assemblies

5. Enhanced Repeatability

• Ultra-precise timing ensures identical pulse profiles every cycle
• Ideal for automated and high-throughput systems

Integration with Sigma Welding Software

SPT is natively integrated into Sigma Laser’s software environment:

Best Practices for Using SPT

🔹 1. Parameter Optimization

• Use short, high-intensity pulses for copper and reflective metals
• Tune frequency to balance heat input and pulse overlap

🔹 2. Material Testing

• Perform weld trials on sample materials to fine-tune SPT settings
• Use high-speed camera or metallurgical inspection to validate weld integrity

🔹 3. Advanced Programming

• Combine SPT with multi-pass strategies for thicker joints
• Integrate with seam tracking for continuous welds in automation

🔹 4. Quality Control

• Use pyrometry or inline sensors to monitor temperature stability
• Log each pulse’s energy and peak power for traceability

Industrial Applications

Summary

Super Pulse Technology (SPT) enhances Sigma Laser’s core software platform by offering:

• Higher energy concentration per pulse
• Superior weld quality in difficult metals
• Seamless integration into automated or manual systems

Together with Sigma’s intuitive interface and real-time control, SPT enables next-generation welding with high precision and repeatability across advanced manufacturing sectors.