Data processing device, data processing system, data processing method, program, and storage medium

Abstract

To provide a data processing apparatus, a data processing system, a data processing method, a program, and a storage medium with which convenience can be improved for data related to welding and inspection.SOLUTION: A data processing apparatus receives, from a welding device that joins a plurality of components to each other to produce a joined body, welding device data including a welding device ID for identifying the welding device. The data processing apparatus receives inspection data including position data and angle data. The position data is calculated from a result of a survey of the joined body using an ultrasonic wave and indicates the position of a welded part in the joined body. The angle data indicates the angle of the welded part. The data processing apparatus links the inspection data to the welding device data.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] FIELD Embodiments of the present invention relate to a data processing device, a data processing system, a data processing method, a program, and a storage medium. [Background technology]

[0002] There are welding devices that weld multiple parts together, and there are also inspection devices that inspect welded joints. In manufacturing lines that include welding and inspection devices, various data related to welding and inspection can be obtained. There is a demand for the development of technology that can improve the usability of this data. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2007-278809 Summary of the Invention [Problem to be solved by the invention]

[0004] The problem to be solved by the present invention is to provide a data processing device, a data processing system, a data processing method, a program, and a storage medium that can improve the convenience of data related to welding and inspection. [Means for solving the problem]

[0005] A data processing device according to an embodiment receives welding device data, including a welding device ID for identifying a welding device, from a welding device that joins multiple parts to create a joint. The data processing device receives inspection data including position data and angle data. The position data is calculated from the results of an ultrasonic probe of the joint and indicates the position of a weld in the joint. The angle data indicates the angle of the weld. The data processing device associates the inspection data with the welding device data. [Brief explanation of the drawings]

[0006] [Figure 1] FIG. 1 is a schematic diagram illustrating a data processing system according to an embodiment. [Figure 2] FIG. 1 is a schematic diagram illustrating a welding device. [Figure 3] FIG. 2 is a schematic diagram illustrating a state of resistance spot welding. [Figure 4] FIG. 2 is a schematic diagram showing current and pressure during resistance spot welding. [Figure 5] 10 is a table illustrating example part data. [Figure 6] 1 is a table illustrating weld data. [Figure 7] 1 is a table illustrating welding device data. [Figure 8] 1 is a table illustrating welding condition data. [Figure 9] 10 is a table illustrating example linkage data. [Figure 10] FIG. 1 is a schematic diagram illustrating an inspection device. [Figure 11] FIG. 2 is a schematic diagram showing the structure of a detector and a bonded body. [Figure 12] 5A and 5B are schematic diagrams for explaining the operation of the inspection device according to the embodiment. [Figure 13] 10 is an example of an image showing a three-dimensional intensity distribution of a reflected wave. [Figure 14] 10 is an example of an image showing a two-dimensional intensity distribution of a reflected wave. [Figure 15] 10 is an example of an image showing an identified welded portion. [Figure 16] FIG. 2 is a schematic diagram showing a detector. [Figure 17] 1 is a table illustrating test data. [Figure 18] 10 is a table illustrating example linkage data. [Figure 19] 3 is a flowchart showing processing by the data processing device according to the embodiment. [Figure 20] FIG. 2 is a schematic diagram illustrating a user interface. [Figure 21] FIG. 2 is a schematic diagram illustrating a user interface. [Figure 22] FIG. 2 is a schematic diagram illustrating a user interface. [Figure 23] FIG. 2 is a schematic diagram illustrating a user interface. [Figure 24] FIG. 2 is a schematic diagram illustrating a user interface. [Figure 25] FIG. 2 is a schematic diagram illustrating a user interface. [Figure 26] FIG. 2 is a schematic diagram illustrating a user interface. [Figure 27] FIG. 2 is a schematic diagram illustrating a user interface. [Figure 28] FIG. 2 is a schematic diagram illustrating a user interface. [Figure 29] 1 is a table illustrating rules. [Figure 30] FIG. 10 is a diagram for explaining an output example. [Figure 31] FIG. 10 is a diagram for explaining an output example. [Figure 32] FIG. 2 is a schematic diagram illustrating a user interface. [Figure 33] FIG. 2 is a schematic diagram showing a hardware configuration. DETAILED DESCRIPTION OF THE INVENTION

[0007] Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the present specification and the drawings, elements similar to those already described are designated by the same reference numerals, and detailed descriptions thereof will be omitted where appropriate.

[0008] FIG. 1 is a schematic diagram showing a data processing system according to an embodiment. The data processing system 1 according to the embodiment includes a data processing device 10, a storage device 20, an output device 30, an input device 40, a welding device 100, and an inspection device 200.

[0009] The data processing device 10 receives data from the welding device 100 and the inspection device 200 and processes the received data. When processing the data, the data processing device 10 appropriately refers to the data stored in the storage device 20. Furthermore, the data processing device 10 appropriately saves the data obtained by processing in the storage device 20. The data processing device 10 causes the output device 30 to output the data. A user can input data to the data processing device 10 using the input device 40.

[0010] Welding device 100 joins a plurality of parts (metal plates) together to produce a joined body. Welding device 100 performs, for example, resistance spot welding. Welding device 100 transmits to data processing device 10 welding device data indicating information about welding device 100 itself, welding condition data indicating the welding conditions used, and welded portion data indicating information about the welded portion.

[0011] The inspection device 200 inspects the joint welded by the welding device 100. The inspection is performed based on data obtained by ultrasonic detection. The inspection device 200 transmits the inspection data obtained by the inspection to the data processing device 10.

[0012] First, a specific example of welding device 100 and various data obtained by welding device 100 will be described.

[0013] (welding equipment) FIG. 2 is a schematic diagram illustrating a welding device. 2, the welding apparatus 100 includes a base 101, a lower arm 110, a lower holder 111, a lower electrode 112, an upper arm 120, an upper holder 121, an upper electrode 122, a guide 131, a movable member 133, a drive unit 134, a power source 140, a current detection unit 141, and a pressure detection unit 142.

[0014] The base 101 is fixed to a predetermined location in the manufacturing site. The lower arm 110 and the upper arm 120 are fixed to the base 101. The lower arm 110 and the upper arm 120 are spaced apart and face each other in the vertical direction. For the sake of explanation, the direction from the lower arm 110 to the upper arm 120 is referred to as "up" and the opposite direction is referred to as "down." These directions are based on the positional relationship between the lower arm 110 and the upper arm 120 and do not imply the direction of gravity. The direction from the lower arm 110 to the upper arm 120 may intersect with the vertical direction.

[0015] The lower holder 111 is attached to the lower arm 110. The lower holder 111 may be movable relative to the lower arm 110. The lower electrode 112 is fixed to the lower holder 111 and protrudes upward.

[0016] The guide 131 is fixed to the upper arm 120. The guide 131 includes a pole 132 extending in the vertical direction. The movable member 133 is attached to the pole 132. The upper holder 121 is fixed to the movable member 133. The upper electrode 122 is fixed to the upper holder 121 and protrudes downward. The lower electrode 112 and the upper electrode 122 face each other in the vertical direction.

[0017] The driving unit 134 moves the movable member 133. The movable member 133 moves along the pole 132. When the movable member 133 moves, the position of the upper electrode 122 in the vertical direction changes relative to the lower electrode 112. In other words, the distance between the lower electrode 112 and the upper electrode 122 in the vertical direction changes.

[0018] The power supply 140 is electrically connected to the lower electrode 112 and the upper electrode 122. The power supply 140 applies a voltage between the lower electrode 112 and the upper electrode 122 during welding. For example, the power supply 140 connects the lower electrode 112 to a ground potential and applies a voltage to the upper electrode 122. This causes a current to flow between the lower electrode 112 and the upper electrode 122.

[0019] During welding, the current detection unit 141 detects the current flowing through the lower electrode 112 and the upper electrode 122. In the illustrated example, the current detection unit 141 is electrically connected between the power supply 140 and the lower electrode 112. The current detection unit 141 includes, for example, an ammeter.

[0020] The pressure detection unit 142 detects the pressure applied to the parts to be welded during welding. In the illustrated example, the pressure detection unit 142 is provided in the upper holder 121 and detects the pressure applied to the upper electrode 122. The pressure applied to the upper electrode 122 is related to the pressure on the parts. In other words, the pressure detection unit 142 indirectly detects the pressure applied to the parts to be welded based on the pressure applied to the upper electrode 122. The pressure detection unit 142 includes, for example, a strain gauge.

[0021] The control device 150 includes a main control unit 151, a current control unit 152, and a drive control unit 153. The main control unit 151 transmits commands to the current control unit 152 and the drive control unit 153. For example, the main control unit 151 transmits various setting values for welding to the current control unit 152 and the drive control unit 153.

[0022] The current control unit 152 is electrically connected to the power supply 140 and the current detection unit 141. The current control unit 152 controls the power supply 140 based on the detection result by the current detection unit 141. For example, the current control unit 152 controls the power supply 140 so that the current flowing through the lower electrode 112 and the upper electrode 122 becomes the set value transmitted from the main control unit 151. Furthermore, the current control unit 152 supplies a current between the lower electrode 112 and the upper electrode 122 for a time period indicated by the set value transmitted from the main control unit 151.

[0023] The drive control unit 153 is electrically connected to the drive unit 134 and the pressure detection unit 142. The drive control unit 153 controls the drive unit 134. For example, the drive control unit 153 controls the drive unit 134 so that the pressure on the parts to be welded becomes the set value transmitted from the main control unit 151.

[0024] The welding apparatus 100 controlled by the control device 150 is not limited to the example shown in Fig. 2, and other known structures may be applied. For example, the welding apparatus may include a manipulator. The lower arm 110, the lower holder 111, the lower electrode 112, the upper arm 120, the upper holder 121, the upper electrode 122, etc. may be provided as an end effector at the tip of the manipulator.

[0025] 3(a) and 3(b) are schematic diagrams showing the state of resistance spot welding. FIG. 3( a) illustrates a process of welding metal plates 310 and 320 by resistance spot welding. First, the metal plates 310 and 320 are placed on the lower electrode 112. The drive unit 134 moves the upper electrode 122 toward the lower electrode 112. The metal plates 310 and 320 are sandwiched and pressed between the lower electrode 112 and the upper electrode 122. In this state, a current i is supplied to the lower electrode 112, the metal plates 310 and 320, and the upper electrode 122. When the current i flows, heat is generated due to the resistance of the metal plates 310 and 320. Portions of the metal plates 310 and 320 melt and mix with each other. The melted portions cool and solidify, forming a weld 330 as shown in FIG. 3( b). The metal plates 310 and 320 are joined together at a weld 330 to form a joined body 300 .

[0026] FIG. 4 is a schematic diagram showing the current and pressure during resistance spot welding. 4, the horizontal axis represents time. The vertical axis represents the magnitude of current and pressure. The solid lines represent changes in the current flowing through the lower electrode 112 and the upper electrode 122. The dashed lines represent changes in pressure applied to the target of resistance spot welding.

[0027] For example, as shown in FIG. 3( a), when the upper electrode 122 moves toward the lower electrode 112 and comes into contact with the metal plate 310, the pressure applied from the upper electrode 122 to the metal plate 310 increases. After the pressure increases to a predetermined value, it is maintained constant. With the pressure maintained at the predetermined value, a pulsed current is supplied to the metal plate 310 and the metal plate 320. After the current is supplied, the metal plate 310 is maintained in a pressurized state. Thereafter, the pressure applied from the upper electrode 122 to the metal plate 310 decreases.

[0028] Standard values are predetermined for each of the pressure increase time T1, pressure application time T2, pressure decrease time T3, squeeze time T4, current application time T5, current off time T6, hold time T7, current value V1, and pressure value V2 shown in Figure 4. The squeeze time T4 is the time from the start of pressure application to the metal plate 310 to the start of current supply. The hold time T7 is the time from the end of current supply to the end of pressure application to the metal plate 310. The current value V1 is the maximum value of the current flowing through the lower electrode 112 and the upper electrode 122. The pressure value V2 is the maximum value of pressure applied to the metal plate 310.

[0029] (data) When welding is performed, the data processing device 10 or the control device 150 identifies the parts to be welded based on the operation logs of various sensors and the transport device, etc. The data processing device 10 accesses the storage device 20 and refers to part data indicating information about the parts to be welded. When the welding device 100 welds multiple parts, the control device 150 transmits weld data, welding condition data, and welding device data to the data processing device 10. The weld data, welding condition data, and welding device data may be transmitted to the data processing device 10 via a higher-level processing device that manages multiple welding devices 100. The data processing device 10 links the weld data to the data of the welded parts. The data processing device 10 also links the weld data, welding condition data, and welding device data to one another.

[0030] Fig. 5 is a table illustrating part data, Fig. 6 is a table illustrating welded portion data, Fig. 7 is a table illustrating welding device data, and Fig. 8 is a table illustrating welding condition data. The part data indicates information about each part to be joined. As shown in Fig. 5, the part data 410 includes a part ID 411, a part name 412, a type 413, a material 414, and a thickness 415. The part ID 411 is a unique character string for identifying the part. The part name 412 is the name of the part. The type 413 indicates the type of the part. The material 414 indicates the material of the part. The thickness 415 indicates the thickness of the part.

[0031] The weld data indicates information about each weld 330. As shown in FIG. 6, the weld data 420 includes a weld ID 421, a weld number 422, a position 423, a plate number 424, a component ID 425, and a component ID 426. The weld ID 421 is a unique character string for identifying the weld. For example, a single joined body 300 has multiple welds 330 formed therein. The weld ID 421 is registered for each weld 330. The weld number 422 is a number for identifying each weld 330 in a single joined body 300. If the joined bodies 300 are of the same type, the same number is assigned to welds 330 located at the same position between the joined bodies 300. The position 423 indicates the position where the weld 330 is formed. The plate number 424 indicates the number of components (metal plates) joined at the weld. The part IDs 425 and 426 indicate the ID of the first part and the ID of the second part, respectively. In this example, one joined body 300 is composed of two parts. If one joined body 300 is composed of three or more parts, the number of registered part IDs increases according to the number of parts.

[0032] The welding equipment data indicates information about each welding equipment. As shown in FIG. 7, the welding equipment data 430 includes a welding equipment ID 431, a welding equipment name 432, an installation location 433, and an operation start date 434. The welding equipment ID 431 is a unique character string for identifying the welding equipment. The welding equipment name 432 is the name of the equipment. The installation location 433 indicates the location where the equipment is installed. The operation start date 434 indicates the time when the equipment started operating. The operation start date 434 indicates the time when the equipment first started operating, not the time when the equipment was restarted after being shut down due to a production line shutdown or after maintenance.

[0033] The welding condition data indicates the conditions under which welding was performed. As shown in FIG. 8, the welding condition data 440 includes a condition data ID 441, a current value 442, a pressure value 443, a pressure duration 444, a welding time 445, an electrode model 446, and a number of consecutive uses 447. The condition data ID 441 is a unique character string for identifying each welding process performed. The current value 442 and the pressure value 443 correspond to the current value V1 and the pressure value V2 shown in FIG. 4. The pressure duration 444 corresponds to the pressure duration T2 shown in FIG. 4. The welding time 445 indicates the time when welding was performed. The model number 446 indicates a model number unique to each type of electrode. By identifying the model, the diameter, overall length, material, precision (tolerance), etc. of the electrode can be confirmed. The number of consecutive uses 447 indicates the number of times the electrode has been used consecutively since it was replaced or polished.

[0034] FIG. 9 is a table illustrating the linking data. As described above, data processing device 10 links weld portion data, welding condition data, and welding equipment data to one another. Furthermore, weld portion data is linked to component data. Welding condition data and welding equipment data are linked to component data via weld portion data. Linking data indicates the link between weld portion data, welding condition data, and welding equipment data. As shown in FIG. 9 , linking data 450 includes linking data ID 451, weld portion ID 421, welding equipment ID 431, and condition data ID 441. Linking data ID 451 is a unique character string assigned to each combination of weld portion ID 421, welding equipment ID 431, and condition data ID 441.

[0035] By referring to the welded portion data and the linked data, the data processing device 10 can search for other linked data based on any of the part data, the welded portion data, the welding equipment data, and the welding condition data.

[0036] Next, a specific example of the inspection device 200 and various data obtained by the inspection device 200 will be described.

[0037] (Inspection equipment) FIG. 10 is a schematic diagram illustrating an inspection device. As shown in FIG. 10, the inspection device 200 includes a control device 210 , a processing device 220 , and a robot 230 .

[0038] The control device 210 controls the operation of the robot 230. The control device 210 is a so-called robot controller. The control device 210 includes a control circuit, a servo control unit, a power supply unit, etc. The control device 210 controls the operation of the robot 230 by controlling the servo motors of each axis in accordance with a pre-stored operation program.

[0039] The robot 230 includes a manipulator 231 and a detector 232 attached to the manipulator 231. For example, the manipulator 231 is a vertical multi-joint type. The detector 232 is provided at the tip of the manipulator 231 as an end effector. The manipulator 231 may be a horizontal multi-joint type or a parallel link type. The manipulator 231 may include a combination of two or more types selected from the vertical multi-joint type, the horizontal multi-joint type, and the parallel link type. The manipulator 231 preferably has six or more degrees of freedom.

[0040] The detector 232 performs probing of the target. The probing includes transmitting ultrasonic waves toward the target and detecting (receiving) the reflected waves. The detector 232 obtains intensity data indicating the intensity of the reflected waves through the probing. The detector 232 transmits the intensity data to the processing unit 220.

[0041] 10, a dispenser 235 and an imaging unit 236 are further provided as end effectors. The dispenser 235 dispenses couplant liquid toward the target surface. The imaging unit 236 captures an image of the weld 330. The processing device 220 calculates the external position of the weld 330 from the obtained image.

[0042] FIG. 11 is a schematic diagram showing the structure of the detector and the assembly. In the example of Fig. 11, the target of detection by detector 232 is a joined body 300. Joined body 300 includes metal plates 310 and 320. Metal plates 310 and 320 are joined at a weld 330. That is, at weld 330, there is no boundary surface between metal plates 310 and 320. At weld 330, there is a solidified portion 340 formed by the molten metals mixing together. Weld 330 is formed by resistance spot welding.

[0043] As shown in FIG. 11, the detector 232 includes a detection element 232a, a propagation portion 232b, and a housing 232c. The detector elements 232a are arranged along the X and Y directions. The X and Y directions intersect with each other. In this example, the Y direction is perpendicular to the X direction. For example, the detector elements 232a are transducers that emit ultrasonic waves with a frequency of 1 MHz or more and 100 MHz or less. The detector elements 232a transmit ultrasonic waves along the Z direction. The Z direction is perpendicular to the XY plane.

[0044] The plurality of detecting elements 232a are provided at the tip of the housing 232c and are covered by the propagation part 232b. When the detector 232 is brought into contact with the bonded body 300, the propagation part 232b is located between the detecting elements 232a and the bonded body 300. When the detecting elements 232a emit ultrasonic waves, the ultrasonic waves propagate through the propagation part 232b and are transmitted to the outside of the detector 232. When the ultrasonic waves are reflected, the reflected waves propagate through the propagation part 232b and reach the detecting elements 232a.

[0045] The detecting element 232a detects the reflected wave. The intensity of the signal detected by the detecting element 232a corresponds to the intensity of the reflected wave. The detector 232 obtains a signal (intensity data) indicating the reflected wave intensity and transmits it to the processing device 220.

[0046] Propagation portion 232b is made of a resin material or the like that allows ultrasonic waves to easily propagate. Propagation portion 232b can suppress deformation, damage, etc. of detection element 232a when detector 232 comes into contact with welded portion 330. Propagation portion 232b has sufficient hardness to suppress deformation, damage, etc. when it comes into contact with welded portion 330.

[0047] During the inspection, a couplant liquid 350 is applied to the surface of the bonded body 300 so that ultrasonic waves can easily propagate between the detector 232 and the bonded body 300. Each detection element 232a transmits ultrasonic waves US toward the bonded body 300 to which the couplant liquid 350 has been applied.

[0048] 11, for example, one detecting element 232a transmits ultrasonic waves US toward the bonded structure 300. A portion of the ultrasonic waves US is reflected by the upper or lower surface of the bonded structure 300. Each of the multiple detecting elements 232a detects the reflected waves RW. In the inspection, each detecting element 232a transmits ultrasonic waves US in sequence, and each reflected wave RW is detected by the multiple detecting elements 232a.

[0049] The processing device 220 processes the strength data and calculates inspection values related to the welded portion 330. The inspection values include one or more selected from the center position, angle, thickness, depth of the depression, and diameter of the welded portion 330. The processing device 220 generates inspection data including the inspection values. The inspection data may include a judgment result as to whether the welded portion 330 is good or bad.

[0050] 12(a) to 12(c) are schematic diagrams for explaining the operation of the inspection device according to the embodiment. As shown in FIG. 12( a ), the ultrasonic waves US are reflected by the surface of the propagation portion 232 b , the upper surface 311 and the lower surface 312 of the metal plate 310 , and the upper surface 331 and the lower surface 332 of the welded portion 330 .

[0051] The positions in the Z direction of the surfaces of the propagation portion 232b, the upper surface 311, the upper surface 331, the lower surface 312, and the lower surface 332 are different from one another. That is, the distances in the Z direction between these surfaces and the detection element 232a are different from one another. When the detection element 232a detects the waves reflected from these surfaces, peaks of the reflected wave intensity are detected. By calculating the time from when the ultrasonic waves US are transmitted until each peak is detected, it is possible to determine from which surface the ultrasonic waves US are reflected.

[0052] 12(b) and 12(c) are graphs illustrating the relationship between the time after transmission of ultrasonic waves US and the intensity of the reflected waves RW at a point in the XY plane. In FIGS. 12(b) and 12(c), the horizontal axis represents the intensity of the detected reflected waves RW. The vertical axis represents the time elapsed after transmission of ultrasonic waves US. Time corresponds to the position in the Z direction. The graph in FIG. 12(b) illustrates the detection results of the reflected waves RW from the surface, upper surface 311, and lower surface 312 of the propagation portion 232b. That is, the graph in FIG. 12(b) illustrates the detection results of the reflected waves RW from a non-bonded point. The graph in FIG. 12(c) illustrates the detection results of the reflected waves RW from the surface, upper surface 331, and lower surface 332 of the propagation portion 232b. That is, the graph in FIG. 12(c) illustrates the detection results of the reflected waves RW from a bonded point.

[0053] 12(b) and 12(c), peak Pe10 is based on the wave RW reflected from the surface of the propagation portion 232b. Peak Pe11 is based on the wave RW reflected from the upper surface 311. Peak Pe12 is based on the wave RW reflected from the lower surface 312. The times from the transmission of the ultrasonic wave US to the detection of peak Pe11 and peak Pe12 correspond to the positions of the upper surface 311 and lower surface 312 in the Z direction, respectively.

[0054] Similarly, peak Pe13 is based on the reflected wave RW from the upper surface 331. Peak Pe14 is based on the reflected wave RW from the lower surface 332. The times from the transmission of the ultrasonic wave US to the detection of peaks Pe13 and Pe14 correspond to the positions of the upper surface 331 and the lower surface 332 in the Z direction, respectively.

[0055] The processing device 220 determines whether a peak Pe12 exists in the reflected wave intensity distribution in the Z direction at each point in the XY plane. Specifically, the processing device 220 detects a peak in a range in the Z direction in which the peak Pe12 can be detected. The processing device 220 compares the peak intensity with a threshold. The range in the Z direction and the threshold are set in advance.

[0056] When the peak intensity exceeds the threshold, the processing device 220 determines that the peak is peak Pe12. The presence of peak Pe12 indicates that a lower surface 312 exists at that point, and that the metal plates 310 and 320 are not joined. The processing device 220 determines that a point at which peak Pe12 is detected is not joined. The processing device 220 determines that a point at which peak Pe12 is not detected is joined. The processing device 220 sequentially determines whether each point in the XY plane is joined. The processing device 220 identifies a set of points determined to be joined as a weld 330.

[0057] The processor 220 may use the intensity data obtained from the probe to generate an image.

[0058] FIG. 13 is an example of an image showing the three-dimensional intensity distribution of reflected waves. In the scanning, as described above, each detecting element 232a sequentially transmits ultrasonic waves, and the reflected waves are detected by the multiple detecting elements 232a. In the specific example shown in FIG. 11, 8 × 8 = 64 detecting elements 232a are provided. In this case, the 64 detecting elements 232a sequentially transmit ultrasonic waves. Each detecting element 232a repeatedly detects the reflected waves 64 times. Each detecting element 232a outputs 64 detection results of the reflected wave intensity distribution in the Z direction. The intensity distributions of the 64 reflected waves output from one detecting element 232a are summed. The summed intensity distribution becomes the intensity distribution at the coordinates where one detecting element 232a is provided in one scanning. Similar processing is performed on the detection results from each of the 64 detecting elements 232a. Aperture synthesis may be performed on the detection results of each detecting element 232a to improve the resolution in the X and Y directions. As a result, the intensity distribution of the reflected wave in the Z direction is generated at each point in the XY plane. In other words, three-dimensional intensity data including the reflected wave intensities at each point in the X, Y, and Z directions is obtained.

[0059] The image in Figure 13 shows the state of the vicinity of the weld 330 based on three-dimensional intensity data. In Figure 13, areas with high brightness are areas where the intensity of the reflected ultrasonic waves is relatively high. In the example in Figure 13, reflected waves from the upper and lower surfaces of the weld 330 and reflected waves that are multiplexed between these surfaces appear.

[0060] 14(a) to 14(c) are examples of images showing the two-dimensional intensity distribution of reflected waves. Processing device 220 may process the intensity data to obtain the data shown in Figures 14(a) to 14(c). Figure 14(a) shows the intensity distribution of the reflected wave in the XY plane near weld 330. Figure 14(b) shows the intensity distribution of the reflected wave in the YZ plane near weld 330. Figure 14(c) shows the intensity distribution of the reflected wave in the XZ plane near weld 330.

[0061] The data in Figure 14(a) is obtained by adding up the intensities in the Z direction at each point on the XY plane. The data in Figure 14(b) is obtained by adding up the intensities in the X direction at each point on the Z direction. The data in Figure 14(c) is obtained by adding up the intensities in the Y direction at each point on the Z direction. In Figures 14(a) to 14(c), the intensities of the reflected waves are shown in a schematic binarized form. White dots indicate that the intensity of the reflected waves at that point is relatively high. Black dots indicate that the intensity of the reflected waves at that point is relatively low.

[0062] FIG. 15 is an example of an image showing the identified weld. FIG. 15 shows the results of the bonded / unbonded determination for each point on the XY plane. The ranges in the X and Y directions of the region where the bonded / unbonded determination is performed correspond to the ranges in the X and Y directions where the intensity data was obtained. As an example, the ranges in the X and Y directions of the two-dimensional data shown in FIG. 15 correspond to the ranges in the X and Y directions of the three-dimensional intensity data shown in FIG. 13, respectively. A portion of the range where the intensity data was obtained may be extracted in the X and Y directions, and the bonded / unbonded determination may be performed for the extracted region. The determination is performed for each point on the XY plane of the intensity data. In FIG. 15, points determined to be bonded based on the intensity data are shown in white. Points determined to be unbonded are shown in black. The set of points determined to be bonded corresponds to the welded portion 330. The processing device 220 generates the image shown in FIG. 15 using the bonded determination results for each point.

[0063] During the inspection, the processing device 220 may further calculate one or more selected from the center position, angle, thickness, depth of the depression, and diameter of the welded portion 330. The method for calculating each value will be described below.

[0064] (position) The processing device 220 calculates the position of the center of gravity of the intensity of the reflected wave on the XY plane shown in Fig. 14(a) as the position of the weld 330. For example, as shown in Fig. 14(a), the position of the center of gravity in terms of luminance may be calculated in a binarized image. Alternatively, the position of the center of gravity in terms of luminance may be calculated in an image in which each pixel has a pixel value of three or more levels (for example, 0 to 255).

[0065] Alternatively, the processing device 220 may extract the reflected wave component from the weld 330 in the Z direction and calculate the center of gravity position. For example, as shown in FIGS. 14(b) and 14(c), the period in which the reflected wave from the weld 330 is detected is different from the period in which the reflected wave from other areas is detected. The processing device 220 filters the intensity distribution in the Z direction using a preset thickness of the weld 330. In this way, the processing device 220 extracts the reflected wave component from the weld 330. The processing device 220 calculates the center of gravity position of the intensity distribution on the XY plane after filtering as the position of the weld 330.

[0066] 15, the processing device 220 may identify the welded portion 330 and calculate the position of its center of gravity on the XY plane as the position of the welded portion 330. As described above, the welded portion 330 can be identified by determining whether each point on the XY plane is joined or unjoined. The processing device 220 may calculate the center of a circle inscribed or circumscribed on the XY plane for the identified welded portion 330 as the position of the welded portion 330.

[0067] The weld 330 formed by resistance spot welding is generally circular. The processing device 220 may use the position calculated by any of the following methods as the position of the weld 330. In a first method, the processing device 220 generates an approximation circle of the weld 330 using the least squares method and calculates the position of the approximation circle. In a second method, the processing device 220 generates the largest inscribed circle that inscribes the outer edge of the weld 330 and calculates the position of the inscribed circle. In a third method, the processing device 220 generates the smallest circumscribed circle that circumscribes the outer edge of the weld 330 and calculates the position of the circumscribed circle. In a fourth method, the processing device 220 calculates the positions of the inscribed circle and circumscribed circle that have the smallest radius difference.

[0068] (angle) FIG. 16 is a schematic diagram showing a detector. The angle of the weld 330 corresponds to the angle between the normal direction D2 of the upper surface of the weld 330 and the direction D1 of the detector 232, as shown in FIG. 16, for example. The direction D1 is perpendicular to the arrangement direction of the multiple detection elements 232a. The angle is represented by the angle θx about the X direction and the angle θy about the Y direction between the directions D1 and D2. In other words, the angle of the weld 330 is the inclination of the upper surface of the weld 330 with respect to the arrangement direction of the multiple detection elements 232a.

[0069] The angle θx is calculated based on the detection result in the YZ plane, as shown in FIG. 14(b). The angle θy is calculated based on the detection result in the XZ plane, as shown in FIG. 14(c). Specifically, the processing device 220 calculates the average of the three-dimensional brightness gradient. The processing device 220 uses the average of the gradient around the X direction as the angle θx. The processing device 220 uses the average of the gradient around the Y direction as the angle θy.

[0070] Here, data indicating the position of the center of welded portion 330 is called position data, and data indicating the angle of welded portion 330 is called angle data.

[0071] (thickness, depth of recess, diameter) The thickness of weld 330 is the distance in the Z direction between upper surface 331 and lower surface 332. The thickness of weld 330 can be calculated based on the time difference between peaks Pe13 and Pe14. The depth of the depression in weld 330 is the distance in the Z direction between upper surfaces 311 and 331. The depth of the depression in weld 330 can be calculated based on the time difference between peaks Pe11 and Pe13. The diameter is the length of weld 330 in any direction parallel to the XY plane. The major diameter or minor diameter may be used as the diameter. The major diameter is the distance between the two most distant points among multiple points on the outer edge of weld 330. The minor diameter is the length of weld 330 in a direction perpendicular to the line segment connecting the two points and passing through the center between the two points.

[0072] (Good / bad judgement) The processing device 220 compares the diameter with a preset threshold. If the diameter exceeds the threshold, the processing device 220 determines that the weld 330 is good. If the diameter is equal to or less than the threshold, the processing device 220 determines that the weld 330 is bad. The diameter compared with the threshold is the major diameter or minor diameter of the weld 330.

[0073] In the examples of FIGS. 12(b) and 12(c) described above, the intensity of the reflected wave RW is expressed as an absolute value. The intensity of the reflected wave may be expressed in any manner. For example, the reflected wave intensity output from the detection element 232a includes positive and negative values depending on the phase. Various processes may be performed based on the reflected wave intensity, including positive and negative values. The reflected wave intensity, including positive and negative values, may be converted to an absolute value. The average value of the reflected wave intensity may be subtracted from the reflected wave intensity at each time. Alternatively, a weighted average value, weighted moving average value, or the like of the reflected wave intensity may be subtracted from the reflected wave intensity at each time. Filtering may be performed so that only frequency components of a specific period are extracted. Even when the results of applying these processes to the reflected wave intensity are used, the various processes described herein can be performed.

[0074] Through the above processing, inspection data based on the inspection results is obtained. When the inspection is performed, the data processing device 10 or the control device 150 identifies the bonded body to be inspected based on the operation logs of various sensors and the transport device. When the inspection device 200 inspects the bonded body, the processing device 220 transmits the inspection data to the data processing device 10. The inspection data may be transmitted to the data processing device 10 via a higher-level processing device that manages multiple inspection devices 200. The data processing device 10 associates the inspection data with other data including welding device data.

[0075] FIG. 17 is a table illustrating the test data. As shown in FIG. 17, the inspection data 460 includes an inspection data ID 461, an inspection device ID 462, an image data ID 463, a position 464a, an appearance position 464b, an angle 465, a thickness 466a, a depression depth 466b, a diameter 467, a determination result 468, and an inspection time 469.

[0076] The inspection data ID 461 is a unique character string for identifying the inspection data. The inspection device ID 462 is a unique character string for identifying the inspection device that acquired the inspection data. The image data ID 463 indicates the ID of the image data obtained in the inspection. The image data is, for example, at least one selected from an image showing the three-dimensional strength distribution shown in FIG. 13, an image showing the joint judgment result shown in FIG. 14(a), an image showing the two-dimensional strength distribution shown in FIG. 14(b) or FIG. 14(c), and an image showing the welded portion shown in FIG. 15.

[0077] Position 464a indicates the position of the center of welded portion 330 calculated from the strength data. Position 464a may be expressed with the pre-designed position of welded portion 330 as the origin. Appearance position 464b indicates the position of welded portion 330 calculated from the image acquired by imaging unit 236. Angle 465 indicates the angle of welded portion 330. Thickness 466a indicates the thickness of welded portion 330. Depth 466b indicates the depth of the depression on the top surface of welded portion 330. Diameter 467 indicates the diameter of welded portion 330. Judgment result 468 indicates the judgment result of whether welded portion 330 is good or bad. Inspection time 469 indicates the time when the inspection was performed.

[0078] When inspection of welded portion 330 is performed, inspection device 200 transmits the inspection data to data processing device 10. Data processing device 10 links the inspection data with component data, welding device data, welding condition data, and welded portion data. Data processing device 10 stores the linked data in storage device 20.

[0079] FIG. 18 is a table illustrating the linking data. 18, inspection data ID 452 is further linked to linked data 450 shown in Fig. 9. This links the part data, welding equipment data, welding condition data, welded portion data, and inspection data to one another. Note that the inspection data does not have to be directly linked to the welding equipment data, welding condition data, and welded portion data, but may be linked to the welding equipment data, welding condition data, and welded portion data via the part data.

[0080] FIG. 19 is a flowchart showing the processing by the data processing device according to the embodiment. Data processing device 10 receives welded portion data, welding condition data, and welding device data from welding device 100 (step S1). Data processing device 10 links the welded portion data, welding condition data, and welding device data to the part data (step S2). Data processing device 10 receives inspection data (step S3). Data processing device 10 links the inspection data to the part data (step S4).

[0081] The advantages of the embodiment will be described. Inspection of the welded portion 330 provides position data indicating the position of the welded portion 330, angle data indicating the angle of the welded portion 330, and the like. These data obtained through the inspection indicate whether there is an abnormality in the welded portion 330. For example, if the position indicated by the position data is deviated from the pre-designed position of the welded portion 330, or if the angle indicated by the angle data is large, these data indicate that there is an abnormality in the welded portion 330. Furthermore, an abnormality in the welded portion 330 indicates that there is an abnormality in the production line of the joined body 300. For example, inspection or maintenance of the welding device 100 may be necessary.

[0082] When an abnormality in the welded portion 330 is found from the inspection data, it is preferable to be able to easily find out where in the production line the cause lies. For example, it is preferable to be able to easily search for the welding device 100 that formed the welded portion 330. When the data processing device 10 according to the embodiment receives inspection data, it links the inspection data to the welding device data. Therefore, when an abnormality in the welded portion 330 is found from the inspection data, it is easy to search for the welding device 100 that formed the welded portion 330. According to the embodiment, welding device data can be easily searched based on the inspection data, improving the usability of the data.

[0083] In particular, the position has a large impact on the quality of the joined structure 300. If the position of the weld 330 is significantly deviated from the design position, the strength of the joined structure 300 may be lower than the designed strength. The position can also be calculated from an image of the weld 330. However, the position of the weld 330 that can be seen externally may be deviated from the actual position of the weld 330 when joined. To more accurately inspect the reliability of the strength, etc. of the joined structure 300, it is desirable to use the actual position of the weld 330. The data processing device 10 links the inspection data, including the position of the weld 330 calculated from the inspection results, to welding equipment data. According to the embodiment, more reliable data can be linked to welding equipment data.

[0084] For improved convenience, the data processing device 10 preferably has at least one of the following functions.

[0085] (User Interface) 20 to 28 are schematic diagrams illustrating examples of the user interface. The output device 30 is, for example, a monitor or a projector. The data processing device 10 displays a graphical user interface (UI) on the output device 30. The data processing device 10 displays, as the UI, a window 500, for example, as shown in FIG. 20 . The window 500 includes a display area 501.

[0086] The data processing device 10 refers to multiple pieces of position data and multiple inspection times for multiple welds 330 with the same number in multiple joined bodies 300. The data processing device 10 displays the change in the position of the weld 330 over time in the display area 501, as shown in Fig. 20. In the example of Fig. 20, the change in the position (X) in the X direction over time (T) and the change in the position (Y) in the Y direction over time (T) are displayed. Alternatively, as shown in Fig. 21, the change in the angle (θx) around the X direction over time (T) and the change in the angle (θy) around the Y direction over time (T) may be displayed.

[0087] A group of icons 503 for selecting data to be displayed may be displayed. The group of icons 503 includes "position," "angle," "thickness," "depth," "diameter," and "judgment." The user can move the pointer 502 by operating the input device 40. When any icon is selected with the pointer 502, data related to the selected icon is displayed. When the icon of "position," "angle," "thickness," "depth," "diameter," or "judgment" is selected, a change in position, a change in angle, a change in thickness, a change in dent depth, a change in diameter, or a change in the judgment result of whether the welding is good or bad over time is displayed.

[0088] The UI may allow a user to select any of the inspection values obtained in the inspection. For example, as shown in FIG. 22 , the user selects any of the inspection values using a pointer 502. When the data processing device 10 accepts the selection of an inspection value, it refers to the inspection data including the selected inspection value. The data processing device 10 displays a window 505 showing other data included in the inspection data. The data processing device 10 may also display a window 507 showing one or more pieces of data selected from component data, weld data, welding condition data, and welding equipment data associated with the inspection data. When other data, such as angle or thickness, is selected, the data processing device 10 can similarly display windows 505 and 507.

[0089] Data processing device 10 may also accept the selection of any data in window 507. Data processing device 10 displays details of the selected data as shown in Figs. 5 to 8 and 17. In the example of Fig. 23, a condition data ID indicating welding conditions is selected in window 507. Data processing device 10 displays window 509 showing welding condition data corresponding to that condition data ID.

[0090] As shown in Fig. 24, when any data is selected, the data processing device 10 may display image data 511 when the inspection data including that data was obtained. In this example, the image data 511 is an image showing the identified welded portion 330. As the image data 511, at least one selected from the image showing the three-dimensional strength distribution shown in Fig. 13, the image showing the joint judgment result shown in Fig. 14(a), the image showing the two-dimensional strength distribution shown in Fig. 14(b) or Fig. 14(c), and the image showing the welded portion shown in Fig. 15 may be displayed.

[0091] While the change in test value over time is being displayed, data processing device 10 may be able to accept the selection of a time. For example, as shown in Fig. 25, when pointer 502 approaches one of the test values, test time 513 at which the test value closest to pointer 502 was obtained is displayed. When a test value or test time 513 is selected, data processing device 10 displays window 505 showing the test data obtained at that test time, as shown in Fig. 26.

[0092] The data processing device 10 may compare the inspection value with a preset threshold value. For example, the data processing device 10 compares the position of the position data or the angle of the angle data with the threshold value. The position data indicates the position of the welded portion 330. The position of the welded portion 330 is expressed with the design position of the welded portion 330 as the origin. In other words, the position of the position data indicates the amount of deviation of the welded portion 330 from the design position. Furthermore, the angle data indicates the angle of the welded portion 330. More specifically, the angle of the welded portion 330 indicates the inclination of the top surface of the welded portion 330 with respect to the orientation of the detector 232 that has been taught in advance.

[0093] When the position exceeds a preset threshold for the position data, or when the angle exceeds a preset threshold for the angle data, the data processing device 10 may output a notification. For example, the data processing device 10 may send a notification to a pre-registered terminal device. The data processing device 10 may also cause the output device 30 to output the notification.

[0094] The data processing device 10 may compare the thickness of the weld 330, the depth of the depression in the weld 330, or the diameter of the weld 330 with a threshold value set in advance for each. If the thickness is smaller than the threshold value, if the depth is larger than the threshold value, or if the diameter is smaller than the threshold value, the data processing device 10 outputs a notification. If the quality of the weld is to be determined, the inspection data includes a determination result of the quality of the weld, which is a comparison result between the diameter and the threshold value. In this case, the data processing device 10 refers to the determination result of the quality of the weld. If the weld is determined to be defective, the data processing device 10 outputs a notification. For example, the data processing device 10 compares the inspection value with a threshold value in response to receiving the inspection value.

[0095] Here, if any of the position, angle, thickness, and diameter is smaller than the threshold, or if the depth is larger than the threshold, the inspection value and welded portion 330 are determined to be "abnormal." For example, a "failure" in welded portion 330 is one type of "abnormal" in welded portion 330. If the inspection value is abnormal, there is a possibility that an abnormality exists in welding device 100 or the conveyance device of joined body 300. If the inspection value exceeds the threshold, a notification is output to alert the user.

[0096] The data processing device 10 may output a notification as appropriate based on the comparison result of the inspection value with the threshold value as well as the change in the inspection value. For example, the data processing device 10 receives the latest inspection data for a weld with a specific number. The data processing device 10 references the immediately preceding inspection data for the weld with the same number. The data processing device 10 references the latest inspection value and the immediately preceding inspection value for the weld with the same number contained in the latest inspection data and the immediately preceding inspection data. If the change in these inspection values exceeds the threshold value, the data processing device 10 outputs a notification.

[0097] Even if the test value is not determined to be abnormal based on the threshold, if the change in the test value is large, there is a possibility that an abnormality exists in the production line. By outputting a notification when the change in the test value is large, it is possible to alert the user.

[0098] Data processing device 10 may display a comparison between the inspection value and the threshold value, as shown in Fig. 27. In the example of Fig. 27, a comparison between the position in the X direction and threshold value THx is shown, and a comparison between the position in the Y direction and threshold value THy is shown. As shown in Fig. 28, when an inspection value exceeds a threshold value, data processing device 10 may display window 505 showing inspection data related to that inspection value and window 515 showing data on the welding equipment that formed welded joint 330 related to that inspection value.

[0099] When an inspection value exceeds a threshold, the data processing device 10 may refer to the welding condition data used when the welded portion 330 corresponding to the inspection value was formed. The data processing device 10 compares the number of consecutive uses of the electrode with the threshold. When the number of consecutive uses falls below a lower limit or exceeds an upper limit, the data processing device 10 outputs a notification. The notification includes one or more notifications selected from a notification indicating a possible defect in the electrode of the welding device and a notification prompting maintenance of the electrode.

[0100] If the electrode is used too many times in succession, it may deteriorate, affecting the characteristics of the weld 330. A low number of consecutive uses of the electrode indicates that the electrode has been used only a few times since it was replaced or polished. If the electrode is used only a few times in succession, there may have been a defect in the electrode replacement or polishing process. In either of these cases, the electrode is presumed to be the cause of the abnormal test value. A notification can be output to inform the user of the possible cause of the abnormality.

[0101] (Modification of welding conditions) If the inspection value is abnormal, the data processing device 10 may modify the welding conditions to improve the inspection value. For example, if the diameter is abnormal, the data processing device 10 increases at least one set value selected from the current value, the pressure value, the current supply time, and the pressure time. The data processing device 10 may directly modify the set value or may transmit the correction rate of the set value to the welding device 100.

[0102] As an example, the metal plates 310 and 320 are made of carbon steel. The thickness of the metal plate 310 in the Z direction is 1.2 mm. The thickness of the metal plate 320 in the Z direction is 1.2 mm. When performing welding, the current value is set to 13 kA. The pressure value is set to 500 kgf. The current application time is set to 60 milliseconds. The current application is repeated twice. The pressure application time is set to 2 seconds. To obtain a shear strength greater than 1000 MPa, the diameter of the welded portion 330 is required to be greater than 6.2 mm. In this case, the threshold value is set to 6.4 mm including a margin.

[0103] For example, if the diameter is less than 6.4 mm, the current value is set to 14 kA. Alternatively, the pressure value may be set to 600 kgf. Alternatively, the current application time may be set to 80 milliseconds. Alternatively, the pressure application time may be set to 2.5 seconds. This allows more energy to be applied to each part during joining, and the diameter of the welded portion 330 can be increased.

[0104] If the thickness of the welded portion 330 is too small, the strength of the welded portion 330 may decrease. Furthermore, for the joined body 300, the thickness of the welded portion 330 is required to be greater than the thickness of the solidified portion 340 by at least a predetermined percentage. For example, the greater the pressure applied to the parts when welding, the smaller the thickness of the welded portion 330. If the thickness is smaller than a threshold, the data processing device 10 reduces the applied pressure or the applied pressure time.

[0105] If the depth of the depression in the welded portion 330 is too large, problems may occur in subsequent processes of the joined body 300. For example, in a painting process, paint may not adhere evenly to the depression in the welded portion 330, resulting in a poor appearance. In a cleaning process, dirt that has entered the depression may not be sufficiently removed. The greater the pressure applied to the parts when welding, the larger the depression. If the depth of the depression is greater than a threshold, the data processing device 10 reduces the applied pressure value or the applied pressure time.

[0106] (Estimated cause) If the test value is abnormal, the data processing device 10 may estimate the cause. For example, the storage device 20 stores correspondence data indicating the correspondence between the event and the cause of the abnormality for each type of abnormality. If the test value is abnormal, the data processing device 10 refers to the correspondence data. The data processing device 10 estimates the cause of the abnormality according to the correspondence data. The data processing device 10 outputs the estimated cause. For example, the data processing device 10 displays the cause on the output device 30. The data processing device 10 may also transmit the cause to a predetermined terminal device.

[0107] 29(a) and 29(b) are tables showing examples of correspondence data. Correspondence data 600a shown in FIG. 29(a) includes anomaly type 601, events 611-616, causes 621-624, and score 630. For example, a condition (threshold) is set in advance for each type of anomaly related to test values. If any of the conditions is met, the test value is determined to have an anomaly that satisfies the condition. Type 601 indicates the type of anomaly that has been determined. Events 611-616 include events related to test values and events related to welding. Causes 621-624 indicate the causes of the anomaly. Score 630 is set for each combination of event and cause and indicates the relationship between the event and the cause.

[0108] In the example of FIG. 29( a), type 601 “large tilt” indicates that the angle of the weld 330 is greater than a preset threshold. Event 611 indicates that an abnormality of the same type as type 601 has occurred in the past in a joint welded by a specific welding device 100. Event 612 indicates that an abnormality of the same type as type 601 has occurred in the past in another weld 330 at the same position as the weld 330 determined to be abnormal, in a joint 300 other than the inspected joint 300. Event 613 indicates that an abnormality occurred within a short period of time after the type of joint 300 being manufactured was changed. Event 614 indicates that the number of consecutive uses of the electrode used in the weld 330 determined to be abnormal is less than a preset threshold. Event 615 indicates that the number of consecutive uses of the electrode used in the weld 330 determined to be abnormal is more than a preset threshold. Event 616 indicates that the positional deviation of the weld 330 from its design position is greater than a preset threshold.

[0109] Cause 621 indicates that the cause of the abnormality lies in the welding device 100. Cause 622 indicates that the cause of the abnormality lies in the lower electrode 112 or the upper electrode 122 of the welding device 100. Cause 623 indicates that the cause of the abnormality lies in the welding conditions used when performing welding. Cause 624 indicates that the cause of the abnormality lies in the transport device that transports the bonded body 300 to the inspection device 200. For each event, a score indicating the relationship is set for each cause. For example, the higher the score, the stronger the relationship between the abnormality and its cause.

[0110] The storage device 20 stores a plurality of conditions for determining each of a plurality of events. When the test value is determined to be abnormal, the data processing device 10 refers to corresponding data linked to the type of abnormality determined. The data processing device 10 compares various data obtained by the data processing system 1 with a plurality of conditions for the plurality of events. The data processing device 10 extracts events that satisfy the conditions. The data processing device 10 obtains a score for each cause of the extracted events according to the corresponding data. The data processing device 10 adds up the scores for each event for each cause. The data processing device 10 determines the cause with the highest score as the cause of the abnormality.

[0111] As an example, when a "large tilt" abnormality is determined and the conditions of events 612 and 615 are satisfied, the score of cause 622 "electrodes" becomes the largest according to the data shown in Fig. 29(a). The data processing device 10 determines that the cause of the "large tilt" is "electrodes."

[0112] The correspondence data 600b shown in FIG. 29(b) includes anomaly type 602, events 611 to 617, and causes 621 to 624. Type 602, "small weld diameter," indicates that the diameter of the weld 330 is smaller than a preset threshold. Event 617 indicates that the angle of the weld 330 is larger than a preset threshold. As an example, when an anomaly of "small weld diameter" is determined and the conditions of events 611 and 612 are satisfied, cause 621, "welding equipment," has the highest score according to the data shown in FIG. 29(b). The data processing device 10 determines that the cause of "small weld diameter" is "weld."

[0113] The correspondence data is prepared in advance by the user. The row items, column items, and scores of the correspondence data may be modified as appropriate after the correspondence data is created. Here, an example has been described in which correspondence data is prepared for each type of abnormality. In addition to this example, multiple correspondence data may be compiled into a single table.

[0114] Alternatively, the determination of the type of anomaly and extraction of the cause may be performed by a model. For example, the model may include an artificial perceptron, a deep neural network, a classifier trained by a random forest, or a Bayesian classifier. The model outputs a determination result of whether an anomaly exists and the cause of the anomaly in response to input of various data from the data processing system 1. The data processing device 10 inputs various data from the data processing system 1 to the model. The data processing device 10 obtains the determination result and the cause from the model.

[0115] The model may include a mathematical model that outputs a determination result of the presence or absence of an abnormality and the cause of the abnormality in response to input of various data from the data processing system 1. The mathematical model is created in advance using regression analysis or the like.

[0116] FIGS. 30(a) to 30(e) and 31(a) to 31(d) are diagrams for explaining output examples. Figures 30(a) and 30(b) are schematic diagrams showing a weld 330 identified in another joint. The outer edges of the images correspond to the outer edges of the area where the inspection was performed. The image shows the location 335 of the center of the weld 330. Figures 30(c) and 30(d) show data for the joint from which the images of Figures 30(a) and 30(b) were obtained, respectively.

[0117] The data in Figure 30(c) relates to a joined body A of type X. The data in Figure 30(d) relates to another joined body B of the same type X. Joint A was welded using welding equipment A. Joint B was welded using welding equipment B. The number of the weld from which the data in Figure 30(c) was obtained is the same as the number of the weld from which the data in Figure 30(d) was obtained. For the data in Figures 30(c) and 30(d), the "center position" indicates the deviation of the center position of the weld 330 from the design position.

[0118] For example, for the joined assembly 300 from which the data in FIG. 30(d) was obtained, the diameter of one weld 330 is small, and the weld 330 is determined to be abnormal. The data processing device 10 refers to the corresponding data related to the abnormality of "small weld diameter." The data processing device 10 determines whether each piece of data shown in FIG. 30(d) satisfies the condition of each event. The data processing device 10 estimates the cause of the abnormality based on the event that satisfies the condition.

[0119] As an example, for the data in FIG. 30(d), it is determined that the "center position" and "equipment operation start" dates and times satisfy the event conditions. Based on these events, it is determined that the welding equipment is the cause of the abnormality. As shown in FIG. 30(d), the data processing device 10 may display a warning mark 523 on the data that satisfies the event conditions. As shown in FIG. 30(e), the data processing device 10 may display a message 527 prompting the user to check the welding equipment. As shown in FIGS. 30(a) and 30(b), data related to another joint welded with the same welding equipment may be displayed.

[0120] 31(a) and 31(c) are examples of other data. For example, for the joined body 300 from which the data in FIG. 31(a) was obtained, the thickness of one weld 330 is small, and the weld 330 is determined to be abnormal. The data processing device 10 references the corresponding data related to the abnormality of "small weld thickness." As shown in FIG. 31(a), the data processing device 10 displays a mark 523 on the data that satisfies the event conditions. Based on the event, it is determined that the cause is the electrodes of the welding equipment. As shown in FIG. 31(b), the data processing device 10 displays a message 527 prompting the user to check the electrodes of the welding equipment.

[0121] For example, for the joined assembly 300 from which the data in FIG. 31(c) was obtained, one weld 330 has a large dent, and the weld 330 is determined to be abnormal. The data processing device 10 references the corresponding data related to the abnormality "large weld dent." As shown in FIG. 31(c), the data processing device 10 displays a mark 523 on the data that satisfies the event conditions. Based on the event, it is determined that the welding conditions are the cause. As shown in FIG. 31(d), the data processing device 10 displays a message 527 prompting the user to check the welding conditions.

[0122] FIG. 32 is a schematic diagram illustrating an example of a user interface. The data processing device 10 may display a score indicating the likelihood of each estimated cause. As shown in Fig. 32, the data processing device 10 may display a window 535 including one or more causes 531 included in the correspondence data and a score 533 for each cause. In this example, each score is normalized so that the sum of the scores is 1. Furthermore, a higher score indicates a relatively higher likelihood that the cause is related to the abnormality.

[0123] The data processing device 10 may receive feedback from the user regarding the cause estimation result, and correct the score of the corresponding data based on the feedback input by the user.

[0124] FIG. 33 is a schematic diagram showing a hardware configuration. The data processing device 10, the control device 150, the control device 210, and the processing device 220 each include, for example, the configuration of a computer 90 shown in Fig. 33. The computer 90 includes a CPU 91, a ROM 92, a RAM 93, a storage device 94, an input interface 95, an output interface 96, and a communication interface 97.

[0125] The ROM 92 stores a program that controls the operation of the computer 90. The ROM 92 stores a program necessary for causing the computer 90 to perform each of the above-described processes. The RAM 93 functions as a storage area in which the programs stored in the ROM 92 are expanded.

[0126] The CPU 91 includes a processing circuit. The CPU 91 uses a RAM 93 as a work memory and executes a program stored in at least one of a ROM 92 and a storage device 94. During program execution, the CPU 91 controls each component via a system bus 98 and executes various processes.

[0127] The storage device 94 stores data necessary for executing the program and data obtained by executing the program.

[0128] The input interface (I / F) 95 connects the computer 90 and the input device 95a. The input I / F 95 is, for example, a serial bus interface such as USB. The CPU 91 can read various data from the input device 95a via the input I / F 95.

[0129] The output interface (I / F) 96 connects the computer 90 and the output device 96a. The output I / F 96 is, for example, a video output interface such as a Digital Visual Interface (DVI) or a High-Definition Multimedia Interface (HDMI (registered trademark)). The CPU 91 can transmit data to the output device 96a via the output I / F 96 and cause the output device 96a to display an image.

[0130] The communication interface (I / F) 97 connects the computer 90 to a server 97a external to the computer 90. The communication I / F 97 is, for example, a network card such as a LAN card. The CPU 91 can read various data from the server 97a via the communication I / F 97.

[0131] The storage device 94 includes one or more selected from a hard disk drive (HDD) and a solid state drive (SSD). The input device 95a includes one or more selected from a mouse, a keyboard, a microphone (voice input), and a touchpad. The output device 96a includes one or more selected from a monitor and a projector. A device having the functions of both the input device 95a and the output device 96a, such as a touch panel, may also be used.

[0132] The functions of the data processing device 10, the control device 150, the control device 210, and the processing device 220 may be realized by cooperation of multiple computers. One computer may function as two or more selected from the data processing device 10, the control device 150, the control device 210, and the processing device 220.

[0133] The various data processing operations described above may be recorded as a computer-executable program on a magnetic disk (such as a flexible disk or hard disk), an optical disk (such as a CD-ROM, CD-R, CD-RW, DVD-ROM, DVD±R, or DVD±RW), a semiconductor memory, or other non-transitory computer-readable storage medium.

[0134] For example, information recorded on a recording medium can be read by a computer (or an embedded system). The recording medium may have any recording format (storage format). For example, a computer reads a program from the recording medium and causes a CPU to execute instructions written in the program based on the program. The computer may acquire (or read) the program via a network.

[0135] The data processing device, data processing system, and data processing method described above allow welding device data to be easily searched for based on inspection data, improving the usability of the data. The same effect can be achieved by using a program that causes a computer to execute the data processing method.

[0136] Although several embodiments of the present invention have been described above, these embodiments are presented by way of example only and are not intended to limit the scope of the invention. These novel embodiments can be embodied in various other forms, and various omissions, substitutions, modifications, etc. can be made without departing from the spirit of the invention. These embodiments and their modifications are included within the scope and spirit of the invention, as well as within the scope of the invention and its equivalents as set forth in the claims. Furthermore, the above-described embodiments can be implemented in combination with each other. [Explanation of symbols]

[0137] 1: Data processing system, 10: Data processing device, 20: Storage device, 30: Output device, 40: Input device, 90: Computer, 91: CPU, 92: ROM, 93: RAM, 94: Storage device, 95: Input interface, 95a: Input device, 96: Output interface, 96a: Output device, 97: Communication interface, 97a: Server, 98: System bus, 100: Welding device, 101: Base, 110: Lower arm, 111: Lower holder, 112: Lower electrode, 120: Upper arm, 121: Upper holder, 122: Upper electrode, 131: Guide, 132: Pole, 133: Movable member, 134: Drive unit, 140: Power supply, 141: Current detection unit, 142: Pressure detection unit, 150: Control device, 151: Main control unit, 152: Current control unit, 153: Drive control unit, 200: Inspection device, 210: Control device, 220: Processing device, 230: Robot, 231: Manipulator, 232: Detector, 232a: Detecting element, 232b: Propagation unit, 232c: Housing, 235: Discharger, 236: Imaging unit, 300: Joint, 310: Metal plate, 311: Upper surface, 312: Lower surface, 320: Metal plate, 330: Welded portion, 331: Upper surface, 332: Lower surface, 340: Solidified portion, 410: Part data, 420: Welded portion data, 430: Welding device data, 440: Welding condition data, 450: Linking data, 460: Inspection data, RW: Reflected wave, T1: Increase time, T2: Pressure time, T3: Decrease time, T4: Squeeze time, T5: Current time, T6: Off time, T7: Holding time, US: Ultrasonic, V1: Current value, V2: Pressure value

Claims

1. receiving welding device data from a welding device that joins a plurality of parts to produce a joined body, the welding device data including a welding device ID for identifying the welding device; receiving inspection data calculated from the result of an ultrasonic probe of the bonded body, the inspection data including position data indicating a position of a weld in the bonded body and angle data indicating an angle of the weld; A data processing device that links the inspection data with the welding device data, receiving a plurality of the welding device data and a plurality of the inspection data; A data processing device that causes an output device to output a plurality of changes in the positions or a plurality of changes in the angles with respect to time.

2. receiving welding device data from a welding device that joins a plurality of parts to produce a joined body, the welding device data including a welding device ID for identifying the welding device; receiving inspection data calculated from the result of an ultrasonic probe of the bonded body, the inspection data including position data indicating a position of a weld in the bonded body and angle data indicating an angle of the weld; A data processing device that links the inspection data with the welding device data, receiving a plurality of the welding device data and a plurality of the inspection data; displaying on an output device a user interface showing the plurality of position changes or the plurality of angle changes with respect to time; accepting, in the user interface, a selection of one of the plurality of positions or one of the plurality of angles; and a data processing device that causes the output device to display one of the plurality of welding device IDs associated with one of the plurality of inspection data including the selected position data or the selected angle data.

3. each of the plurality of inspection data further includes at least one data selected from an image showing the weld based on the result, a thickness of the weld, a depth of a depression on the surface of the weld, and a diameter of the weld; The data processing device according to claim 2 , further causing the output device to display the at least one piece of data included in the one piece of the plurality of inspection data when the selection of any one of the plurality of positions or any one of the plurality of angles is accepted.

4. 4. The data processing apparatus according to claim 2, further causing the output device to display welding condition data indicating welding conditions for any one of the plurality of positions or any one of the plurality of angles selected.

5. 5. The data processing device according to claim 4, wherein the welding condition data further includes one or more selected from a current value applied to the plurality of parts, a pressure applied to the plurality of parts, a time for applying pressure to the plurality of parts, and a number of consecutive uses of an electrode in the welding device.

6. 6. The data processing device according to claim 1, further comprising: a notification output when the position of the position data or the angle of the angle data exceeds a threshold value.

7. The data processing device according to claim 6 , further comprising: an output device configured to output at least one of the inspection data and the welding device data when the position or the angle exceeds a threshold value.

8. receiving welding condition data indicating the conditions of welding performed by the welding device identified by the welding device ID and including the number of consecutive uses of electrodes in the welding device; If the position or the angle exceeds a threshold, it is determined whether the number of consecutive uses is below a lower limit or above an upper limit; 8. The data processing device according to claim 6, wherein when the number of consecutive uses falls below the lower limit or exceeds the upper limit, one or more of a notification indicating a possible defect in the electrode and a notification urging maintenance of the electrode are output.

9. 9. The data processing device according to claim 1, wherein the welding device data includes an operation start date of the welding device.

10. further receiving weld data including data for identifying the weld in the assembly; The data processing device according to any one of claims 1 to 9, wherein the welded portion data is stored in association with the inspection data and the welding device data.

11. 11. The data processing device according to claim 1, wherein, when the position or the angle exceeds a threshold value, conditions for welding performed by the welding device are modified.

12. 12. The data processing device according to claim 1, wherein, when the position or the angle exceeds a threshold, an output device is caused to output an estimation result of the cause of the position or the angle.

13. The data processing apparatus according to claim 12 , wherein the output device is caused to output a plurality of the causes and a plurality of scores indicating the likelihood of each of the causes.

14. the results of the survey include intensity data indicative of the intensity of the reflected waves of the ultrasonic waves from the weld; 14. The data processing device according to claim 1, wherein the position of the weld is a center position of the weld in the strength data.

15. The data processing device according to claim 14 , wherein the center position is the center of gravity position of the weld in the strength data.

16. A data processing device according to any one of claims 1 to 15; an inspection device that performs the probe and generates the inspection data; A data processing system comprising:

17. 17. The data processing system of claim 16, further comprising the welding device.

18. The processing device receiving welding device data from a welding device that joins a plurality of parts to produce a joined body, the welding device data including a welding device ID for identifying the welding device; receiving inspection data calculated from the result of an ultrasonic probe of the bonded body, the inspection data including position data indicating a position of a weld in the bonded body and angle data indicating an angle of the weld; The inspection data is stored in association with the welding device data.

1. A data processing method comprising: The processing device includes: receiving a plurality of the welding device data and a plurality of the inspection data; displaying on an output device a user interface showing the plurality of position changes or the plurality of angle changes with respect to time; accepting, in the user interface, a selection of one of the plurality of positions or one of the plurality of angles; displaying, on the output device, one of the plurality of welding device IDs associated with one of the plurality of inspection data including the selected position data or the selected angle data; Data processing methods.

19. The processing device receiving welding device data from a welding device that joins a plurality of parts to produce a joined body, the welding device data including a welding device ID for identifying the welding device; receiving inspection data calculated from the result of an ultrasonic probe of the bonded body, the inspection data including position data indicating a position of a weld in the bonded body and angle data indicating an angle of the weld; The inspection data is stored in association with the welding device data.

1. A data processing method comprising: The processing device includes: receiving a plurality of the welding device data and a plurality of the inspection data; displaying on an output device a user interface showing the plurality of position changes or the plurality of angle changes with respect to time; Accepting a selection of any of the times in the user interface; displaying one of the plurality of test data obtained at the selected time on the output device; Data processing methods.

20. the results of the survey include intensity data indicative of the intensity of the reflected waves of the ultrasonic waves from the weld; 20. The data processing method according to claim 18, wherein the position of the weld is a center position of the weld in the strength data.

21. The data processing method according to claim 20 , wherein the center position is the center of gravity position of the weld in the strength data.

22. A program that causes a processing device to execute the data processing method according to any one of claims 18 to 21.

23. A storage medium storing the program according to claim 22.

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