This paper presents a position gauging system of welding joints. While the principle measurement concept was already introduced by Schrattenecker et al. in 2014, here it is focused on different types of practically used welding materials. The sensor used is based on the frequency-modulated continuous-wave principle operating in the W-band. Position estimation (PoE) of different welding geometries is carried out with polarimetric scattering effects introduced by geometrical discontinuities. For the real-time calculation of the signal models a field simulation tool we developed is used. Aside from a variety of geometries, we introduce a geometrical optimization approach that increases the achievable accuracy of the measurement concept. The optimization and PoE of the different welding materials were examined in various simulations and the results were verified by measurements in the laboratory and in an industrial environment. Simulation and measurement were in good agreement.

We present the implementation of a cooperative radar system on a gantry rail crane for distance measurements in an industrial environment. The measurement approach is based on the dual-ramp frequency-modulated continuous-wave principle, using identical sensor-nodes at the endpoints of the range of interest. Pseudo-range information is exchanged via a dedicated data-link between these stations. At the sensor-node a flexible high-performance signal processing and remote management engine is implemented. The system setup is controlled by a single host-PC, which is used as a man–machine interface for configuration of the remotely controlled measurement stations, system surveillance, and visualization of the measurement data. Indoor characterization of the developed hardware is sufficient for an efficient calibration of the system, minimizing distance offsets. On-site measurements at distances up to 1000 m with an accuracy better than 2 cm confirm the performance of the ranging system. Furthermore, the results are verified by simulation.

In this paper, we present the results of using a frequency-stepped continuous-wave radar system to estimate the position of overlapping and electrically good conductive plates. We especially focus on polarimetric scattering effects caused by the step of a lap joint, which is a common welding-geometry. To model the step's contribution to the overall scattered signal, we use a two-dimensional combined field integral equation (CFIE) approach. For demonstrating its practical applicability, the implemented scattering model is verified by measurements. To emphasize the improvements of position estimation by using a CFIE approach, the outcomes of the model are compared to a commonly used point scattering model. Finally, the numerical signal is utilized to precisely estimate the position of the lap joint.