Jig-Mounted AE Sensor for Welding Abnormality Detection
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Solution Overview
Problem
In the welding process, existing methods for abnormality determination and estimation using acoustic emission sensors face challenges such as reduced detection accuracy and increased productivity loss due to sensor placement and destruction tests, especially in laser welding where elastic waves are weak and difficult to detect without disrupting the process.
Innovation Solution
An abnormality determination and estimation device featuring a jig device with a chuck mechanism to hold the weld product securely and an AE sensor integrated within the jig to detect elastic waves, allowing for improved detection accuracy and discrimination of abnormalities like welding penetration depth, bead length, and skip without disrupting the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the AE sensor is disposed directly to the weld product in each welding process, then the detection accuracy for abnormality is improved, but the process number increases and productivity is lowered
Solution Approach 1:
The patent introduces a jig device as an intermediary medium between the AE sensor and the weld product. The jig device includes a holding face that contacts the workpiece and transmits elastic waves to the AE sensor, eliminating the need for direct sensor attachment to the weld product and avoiding process interruption
Solution Approach 2:
The jig device serves dual functions: it holds the workpiece during welding and simultaneously acts as a medium for elastic wave transmission to the AE sensor. This self-service approach integrates detection functionality into the existing welding fixture without adding separate detection steps
2Measurement precision
If the AE sensor is put on and taken off in each welding process, then the detection accuracy is improved, but the process complexity increases
Solution Approach 1:
The jig device serves as a permanent intermediary structure that remains in place throughout welding operations, providing a stable mounting position for the AE sensor and eliminating the need for repeated sensor attachment and detachment procedures
3Reliability
If a destruction test is used for abnormality estimation, then the abnormality can be estimated, but the joint portion has to be destroyed
Solution Approach 1:
The patent replaces the mechanical destruction test with acoustic emission detection. By monitoring elastic waves generated during welding, the system can estimate abnormalities and assess joint quality without physically destroying the welded joint
Solution Approach 2:
The jig device with holding face acts as an intermediary that enables non-destructive detection by transmitting elastic waves from the weld joint to the AE sensor, allowing abnormality estimation without direct contact with or damage to the joint portion
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
The solution enhances detection accuracy for welding abnormalities, reduces productivity losses by maintaining continuous welding operations, and effectively discriminates defects without the need for destructive tests, thereby improving overall process efficiency.
Implementation Method 1
an elastic wave generated in a weld product by a welding process is used for determining and estimating an abnormality of the weld product
Data Source
AI summary
An abnormality determination and estimation device for a weld product in a welding process includes a jig device and an AE sensor. The jig device holds the product by a holding face, through which the jig device and the product are in close contact with each other. The AE sensor detects an elastic wave in the jig device. Accordingly, abnormality detection accuracy can be improved, and abnormalities can be discriminated.