Optical Weld Bead Analysis for Real-Time Strength Assessment
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Solution Overview
Problem
Current methods for inspecting welds, such as destructive analysis and surface-altering non-destructive techniques, are either time-consuming or undesirable, as they can damage the components and alter the surface, failing to provide real-time, non-destructive assessment of weld integrity and quality.
Innovation Solution
A system incorporating a robot control module, weld control module, and vision sensor that optically measures distances along the weld bead to determine its strength and characteristics in real-time, using parameters like voltage, current, feed rate, and shield gas flow, allowing for non-destructive analysis of weld quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If destructive analysis or surface-altering non-destructive techniques are used to inspect welds, then weld quality assessment is achieved, but components are damaged or surfaces are altered
Solution Approach 1:
The patent replaces mechanical contact-based inspection methods (destructive testing, surface-altering techniques) with optical sensing. The vision sensor uses light to measure weld bead geometry non-contactly, eliminating physical damage to components while providing comprehensive weld quality assessment through 3D surface profiling
Solution Approach 2:
The patent introduces optical fields as an intermediary between the inspection system and the weld bead. Light reflects off the weld surface and is captured by the vision sensor, enabling indirect measurement of weld geometry without direct contact or damage to the workpiece
2Reliability
If destructive analysis is used to assess weld integrity, then weld quality is determined, but inspection time is excessive
Solution Approach 1:
The patent enables continuous weld inspection by integrating the vision sensor with the welding robot system. The sensor continuously tracks the weld bead geometry in real-time as the welding process progresses, providing ongoing quality assessment rather than discrete post-process inspection points
Solution Approach 2:
The patent performs weld quality assessment during or immediately after the welding process itself, before the workpiece leaves the welding station. This preliminary inspection eliminates the need for separate, time-consuming post-processing analysis and enables immediate detection of defects
3Loss of information
If real-time weld monitoring is implemented, then immediate feedback on weld quality is provided, but system complexity increases
Solution Approach 1:
The patent employs a multi-functional integrated system where the vision sensor serves multiple purposes: it monitors weld bead geometry, tracks weld pool characteristics, and verifies weld parameters throughout the process. This single optical system replaces multiple separate inspection devices, reducing overall system complexity while providing comprehensive real-time feedback
Solution Approach 2:
The patent combines the vision sensor, welding power source control, and robot motion control into an integrated monitoring system. Data from the optical sensor is merged with welding parameters and robot position information to provide unified real-time feedback, eliminating the need for separate complex systems for each function
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 real-time, non-destructive assessment of weld quality, preventing damage to components and providing immediate feedback on weld integrity, reducing the risk of premature failure and corrosion by identifying defects and ensuring consistent stress distribution across the weld.
Implementation Method 1
a vision sensor configured to, during the welding, optically measure N distances between the vision sensor and N locations, respectively, on an outer surface of a weld bead
Data Source
AI summary
A weld system includes: a robot control module configured to actuate a robot and move a welder along a joint of metal workpieces during welding, the welder being attached to the robot; a weld control module configured to, during the welding, apply power to the welder, supply a shield gas, and supply electrode material; a vision sensor configured to, during the welding, optically measure distances between the vision sensor and locations, respectively, on an outer surface of a weld bead created along the joint by the welder; and a weld module configured to: determine a strength of the weld bead at a location based on: the distances at the location along the joint; and at least one parameter from at least one of the robot control module during the welding, the weld control module during the welding, and a sensor configured to capture data of the welding during the welding.