Infrared Spectral Absorption for Non-Destructive Weld Quality Checks
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Solution Overview
Problem
Conventional methods for assessing weld quality are destructive, time-consuming, and prone to human error, requiring repeated inspections and adjustments to achieve satisfactory weld joints.
Innovation Solution
A non-destructive method using infrared light with a wavelength matching the welding energy to assess weld quality objectively, measuring absorption patterns to determine weldability and adjust parameters automatically, eliminating the need for human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional destructive inspection methods are used to assess weld quality, then weld quality can be determined through visual inspection, but the process is time-consuming and requires repeated welding and inspection cycles
Solution Approach 1:
The patent replaces the mechanical destructive inspection process (cutting and visual examination) with an optical measurement system that uses infrared light to assess weld quality non-destructively. The light source emits infrared radiation that interacts with the weld joint, and sensors detect the transmitted or reflected light to determine weld quality parameters, eliminating the need for physical destruction and repeated cycles.
Solution Approach 2:
The patent introduces infrared light as an intermediary medium to assess weld quality. The infrared light serves as a mediator that carries information about the weld joint's internal structure and quality without physically contacting or damaging the weld, enabling remote and non-destructive measurement.
2Measurement precision
If conventional visual inspection by trained weld inspectors is used, then subjective assessment of weld quality can be obtained, but the process is prone to human error and requires specialized training
Solution Approach 1:
The patent replaces the human inspector's visual assessment system with an automated optical measurement system. The system uses light sources, sensors, and processing electronics to objectively measure weld quality parameters, eliminating subjectivity and human error while reducing the need for specialized training.
Solution Approach 2:
The inspection system performs self-assessment of weld quality through automated optical measurements and data processing. The system independently determines weld quality without requiring human intervention or subjective judgment, making the inspection process more reliable and easier to operate.
3Reliability
If destructive cutting and slicing is performed to inspect weld joints, then internal weld quality can be visually assessed, but the parts are physically altered and cannot be reused
Solution Approach 1:
The patent replaces the mechanical cutting and slicing process with an optical measurement process. Infrared light penetrates or reflects from the weld joint to provide information about internal quality without physically removing or altering any material, preserving part integrity while maintaining reliable quality assessment.
Solution Approach 2:
The patent uses infrared light as an intermediary to access internal weld quality information without physical contact. The light acts as a probe that carries diagnostic information about the weld's internal structure and potential defects without requiring physical destruction of the joint.
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 repeatable and consistent weld joints by objectively assessing weld quality without physical alteration of the parts, reducing time and error, and ensuring optimal weld parameters are set for subsequent welds.
Implementation Method 1
The object is a material that absorbs a portion of the light emitted by the laser
Implementation Method 2
The light source includes a back plate that reflects light emitted through a bottom of the object
Data Source
AI summary
Identifying object characteristic based on a contrast ratio of an amount of light reflected or absorbed by the object. Part of the object is illuminated, where the object is a material that absorbs or reflects light emitted by the light source. An amount of light absorbed/reflected by the object is measured. A contrast ratio of the absorbed/reflected light is determined by comparing an amount of light absorbed/reflected by the object to a default absorption or reflection value to obtain a difference between the amount of light absorbed/reflected by the object and the default absorption/reflection value. A characteristic of the object is determined based on the contrast ratio. The wavelength of the light from the light source can be substantially the same as the wavelength of the energy used to form the object by a welding process that uses energy to join at least two parts together to form the object.