Collision Welding Flash Monitoring for Real-Time Seam Quality
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Solution Overview
Problem
Collision welding methods, such as magnetic pulse welding, face challenges in quality control, as the quality of the welding seam can only be checked after the process is completed, requiring additional devices like ultrasound tools, making the process longer and less cost-effective.
Innovation Solution
A method and device that monitor the welding seam during the process by detecting a light flash between joining partners using an optical capture unit, analyzing its characteristics (beginning, duration, intensity, and intensity distribution) against target values to assess the seam quality in real-time, allowing for immediate quality control without additional instruments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If collision welding is performed without real-time monitoring, then the welding process is simple and cost-effective, but the quality of the welding seam cannot be checked during the process and requires additional examination devices after welding
Solution Approach 1:
The patent uses light flash as an intermediary phenomenon that naturally occurs during collision welding. By detecting and analyzing this light flash, the system obtains quality information about the welding seam without requiring direct contact or complex measurement devices at the welding zone. The light flash serves as a mediator that carries information about the welding process quality.
Solution Approach 2:
The patent replaces mechanical/physical examination devices (such as ultrasound devices mentioned in the background) with an optical detection system. Instead of using mechanical contact or acoustic waves to inspect the welding seam after formation, the system uses optical detection of the light flash that occurs during welding, substituting a simpler optical system for complex post-welding examination equipment.
2Measurement precision
If additional examination devices such as ultrasound devices are used to check welding seam quality, then measurement precision is improved, but the production process becomes longer and less cost-effective
Solution Approach 1:
The patent performs quality detection during the welding process itself rather than after welding is complete. By analyzing the light flash characteristics (duration, intensity, temporal distribution) as the welding is occurring, the system determines welding seam quality in advance, before the workpiece needs to be transported to separate inspection stations. This preliminary detection eliminates post-welding examination steps.
Solution Approach 2:
The patent merges the welding process and quality detection into a single integrated operation. The optical detection system operates simultaneously with the collision welding process, combining what were previously separate operations (welding followed by inspection) into one concurrent process, thereby eliminating idle time and improving productivity.
3Loss of time
If real-time monitoring of light flash characteristics is implemented, then welding seam quality can be assessed during the process, but the complexity of the monitoring system increases
Solution Approach 1:
The patent extracts only the essential quality information from the complex welding process by focusing specifically on light flash characteristics (duration, intensity, temporal distribution). Instead of monitoring all parameters of the welding process simultaneously, the system isolates and analyzes only the light flash signal, which contains sufficient information to determine welding seam quality. This extraction approach simplifies the monitoring system compared to comprehensive multi-parameter monitoring.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables cost-effective, nondestructive quality control of welding seams during the process, ensuring only qualified components are further processed, thereby increasing efficiency and reducing production time.
Implementation Method 1
a light flash between the first joining partner and the second joining partner is detected during the welding by an optical capture unit, which measures in a time-resolved manner
Implementation Method 2
a first joining partner and a second joining partner are accelerated toward one another by an introduction of energy and are welded to one another to form the welding seam
Data Source
AI summary
The present invention relates to a method and a device for monitoring the process for a welding seam formed by means of collision welding, in which a first joining partner (1) and a second joining partner (2) are moved toward one another by an introduction of energy and are welded to one another to form the welding seam. A light flash between the first joining partner (1) and the second joining partner (2) is detected during the welding by an optical capture unit (6), which measures in a time-resolved manner, having at least one detector (19, 20, 24) and an actual value of a beginning of the light flash, a duration of the light flash, an intensity of the light flash, and/or an intensity distribution over time of the light flash is determined by an analysis unit (16) and compared to a respective target value of the beginning of the light flash, the duration of the light flash, the intensity of the light flash, and/or the intensity distribution over time of the light flash. The weld seam is only classified as qualitatively adequate if a maximum deviation of the actual value from the target value is maintained.