Joining Line Monitoring with Synchronized Defect Localization
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Solution Overview
Problem
Existing joining quality control methods for solder and brazing processes face challenges in ensuring consistent quality, particularly in large or complex structures, due to unclear temperature changes and limitations in automation, leading to incomplete joints and operation delays.
Innovation Solution
A joining process line monitoring system that acquires and synchronizes phenomenon and operation state data to calculate evaluation data, extracts differences from reference data, and presents abnormal locations, enabling real-time quality control and prevention of defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature measurement is performed in joining processes, then quality control is improved, but it remains unclear whether molten metal material is supplied to the joining location, leading to incomplete portions
Solution Approach 1:
The patent combines multiple measurement functions into a single integrated system. The imaging device captures both temperature distribution (via thermal imaging) and molten metal material flow (via optical imaging) simultaneously, merging previously separate measurement capabilities into one comprehensive monitoring system that provides complete joining process information.
Solution Approach 2:
The imaging device performs multiple functions: it measures temperature distribution, observes molten metal material supply, monitors joining process dynamics, and provides visual records. This multi-functional approach replaces multiple specialized devices with a single universal imaging system that captures comprehensive process data.
2Productivity
If automation is implemented in joining operations, then productivity is improved, but automation cannot be performed in joining operations for large structures or complicated shapes that involve human operation
Solution Approach 1:
The system enables operators to work more effectively by providing real-time process information and automated monitoring. The imaging system serves the operator by automatically detecting abnormalities, measuring temperatures, and recording process data, allowing the operator to focus on complex manual tasks while the system handles measurement and monitoring functions.
Solution Approach 2:
The imaging system acts as an intermediary between the joining process and the operator. It captures process data, processes information about temperature and material flow, and presents actionable insights to the operator, bridging the gap between manual operation and automated monitoring for complex structures.
3Reliability
If destructive inspection or non-destructive inspection is performed to detect joining defects, then quality control is improved, but process delay occurs due to reworking
Solution Approach 1:
The system performs preliminary detection of joining abnormalities during the joining process itself, rather than after completion. By monitoring temperature distribution and molten metal material supply in real-time, the system identifies potential defects before they become actual quality issues, allowing for immediate correction without rework.
Solution Approach 2:
The system provides real-time feedback during the joining process by continuously monitoring process parameters and comparing them against expected values. When abnormalities are detected, the system immediately notifies operators, enabling real-time process adjustment and preventing defect formation, thereby eliminating the need for subsequent inspection and rework cycles.
Data Source
AI summary
The disclosure provides a joining process line monitoring system capable of preventing joining quality deterioration and operation delay. A joining process line monitoring system 100 includes a joining phenomenon data acquisition part 111 configured to acquire a joining phenomenon of a joining subject member as phenomenon data; an operation state data acquisition part 112 configured to acquire a joining operation state of the joining subject member as operation state data; an evaluation data calculation unit 120 configured to perform time synchronization of the acquired phenomenon data and the acquired operation state data, and associate the acquired phenomenon data and the acquired operation state data with each joining operation location, so as to calculate evaluation data; a difference data extraction unit 130 configured to extract a difference between the evaluation data and reference data set in advance as difference data; an abnormal location determination unit 140 that determines that a portion having a large difference from the joining phenomenon is an abnormal location; and a presentation unit 150 configured to present the abnormal location of a joining portion of the joining subject member based on the difference data.