Sensorized Hammer Testing for Non-Destructive Weld Fault Detection
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Solution Overview
Problem
Existing methods for detecting welding faults in vehicle parts, such as visual inspection and cutting inspection, are inadequate as they either fail to identify depth or misalignment of welds or require destruction of parts for accurate sampling.
Innovation Solution
A fault detection apparatus utilizing a hammer device with a force sensor and vibration sensor, which applies an external force to the target part and calculates a frequency response function to determine if peak values are detected in predetermined regions, indicating a fault.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If visual inspection method is used, then total inspection can be performed, but welding depth and misalignment cannot be identified
Solution Approach 1:
The patent replaces visual inspection with a mechanical impact testing system that uses a hammer device to apply controlled forces and sensors to detect welding faults. The force sensor measures impact forces while the acceleration sensor detects vibrations, enabling detection of welding depth and misalignment issues that visual inspection cannot identify.
Solution Approach 2:
The patent introduces sensors (force sensor and acceleration sensor) as intermediaries between the hammer impact and the inspection system. These sensors mediate the detection process by converting mechanical impacts into measurable signals, allowing indirect detection of welding quality without direct visual observation of the weld interior.
2Measurement precision
If cutting inspection method is used, then welding fault can be accurately determined, but parts must be destroyed and only sampling inspection can be performed
Solution Approach 1:
The patent replaces the destructive cutting inspection method with a non-destructive mechanical impact testing system. By using controlled hammer impacts and sensor measurements, the system can accurately detect welding faults without destroying the part, enabling total inspection of all components rather than sampling.
Solution Approach 2:
The hammer device applies self-generated controlled impacts to the workpiece, and the workpiece itself serves as the test object. The system uses the workpiece's own structural response to impacts to reveal welding faults, eliminating the need for external destructive testing procedures.
3Stability of the object's composition
If hammer device with elastic body is used, then vibration can be absorbed, but device complexity increases
Solution Approach 1:
The patent uses an elastic body as a flexible element in the hammer device structure. This elastic body absorbs vibrations generated during impact operations, stabilizing the system by reducing unwanted vibrations while adding only minimal structural complexity compared to rigid alternatives.
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 accurate total inspection of welding faults without destroying the parts, allowing for quick identification of faulty components by comparing frequency response functions with those of good products.
Implementation Method 1
an elastic body provided on the upper body
Implementation Method 2
The support may be formed of an elastic material to absorb vibration of the hammer and the elastic body
Data Source
AI summary
An embodiment hammer device includes a driver, an upper body configured to move in a direction set by power generated from the driver, an elastic body provided on the upper body, a hammer provided in the elastic body, a force sensor provided in the hammer, and a support configured to support the elastic body and the hammer.