Panel Welding Quality Diagnosis via Vibration Stiffness Analysis
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Solution Overview
Problem
Existing methods for diagnosing the quality of spot welding in vehicle body components, such as door hoods, face challenges in accurately determining the real binding force of welding portions due to reduced accuracy and difficulty in frequency analysis.
Innovation Solution
A joining quality diagnosis device that uses a vibration transferring member to scan a target object with multiple welding spots, determining bending stiffness at various locations and identifying areas with low stiffness for potential poor welding quality, employing a system with an oscillator, sensors, and access members to analyze vibration characteristics and display results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If ultrasonic wave projection and frequency analysis are used to diagnose welding quality, then welding portion quality can be determined, but measurement time increases and accuracy deteriorates due to difficulty in frequency analyzing
Solution Approach 1:
The patent extracts only the essential vibration characteristic (resonance frequency) from the complex ultrasonic wave analysis, eliminating unnecessary frequency analysis steps while retaining the core diagnostic capability. This allows rapid identification of welding quality issues without the time-consuming comprehensive frequency analysis of traditional methods.
Solution Approach 2:
The patent applies preliminary action by pre-selecting the resonance frequency range specific to welding portions before measurement. By preparing the vibration excitation parameters in advance and focusing on the critical resonance frequency band, the system achieves rapid diagnosis without needing to perform broad-spectrum frequency analysis during measurement.
2Loss of information
If traditional frequency analysis methods are used to determine welding quality, then welding portion characteristics can be analyzed, but it becomes difficult to accurately determine real binding force
Solution Approach 1:
The patent introduces resonance frequency as an intermediary parameter that directly correlates with welding binding force. Instead of attempting to analyze complex frequency spectra, the system uses the resonance frequency peak as a mediator that translates vibration characteristics into binding force information, simplifying the measurement while improving accuracy.
Solution Approach 2:
The patent changes the measurement parameter from comprehensive frequency analysis to specific resonance frequency detection. By shifting from analyzing the entire frequency spectrum to measuring only the critical resonance frequency peak, the system captures the essential binding force information more accurately and efficiently.
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
This solution reduces measurement time, improves user accessibility, and directly determines the stiffness of welded areas, enabling accurate identification of poor welding quality and potential areas needing additional spot welding.
Implementation Method 1
an oscillator set so as to supply vibration having a predetermined frequency to the one end portion of the vibration transferring member
Implementation Method 2
a sensor disposed apart as a predetermined distance from the oscillator and contacted with the vibration transferring member so as to detect characteristic of vibration moving along the vibration transferring member
Data Source
AI summary
A device for evaluating quality of welding spots of a panel is disclosed. The device includes a vibration transferring member, a first access member contacted with one surface of one end portion of the vibration transferring member and with the one surface of the panel, a second access member contacted with one surface of the other end portion of the vibration transferring member and with the one surface of the panel, an oscillator for supplying vibration to the one end portion of the vibration transferring member, a sensor disposed on the vibration transferring member to detect characteristic of vibration transferred along the vibration transferring member, and a computing device for analyzing characteristic of the welding spots using characteristic of vibration detected in the sensor.