Programmable Weld Signal Evaluation for Real-Time Quality Checks
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Solution Overview
Problem
Existing systems for nondestructively evaluating weld quality in resistance welding require high sampling rates and specialized measurement apparatuses, leading to increased effort and cost in construction.
Innovation Solution
An evaluation system comprising an analog-to-digital converting section using a programmable circuit to convert welding current, voltage, load, and displacement signals into digital form, allowing for real-time evaluation based on predetermined conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If specialized measurement apparatuses are used to achieve rapid nondestructive weld quality evaluation, then measurement precision and speed are improved, but device complexity and construction cost increase
Solution Approach 1:
The patent applies universality by designing an evaluation system that can handle multiple types of measurement apparatuses through a standardized interface. The analog-to-digital converting section and evaluating section are configured to work with different physical quantity acquiring sections (welding current, voltage, load, displacement sensors) using a common architecture, eliminating the need for specialized apparatuses for each measurement type.
Solution Approach 2:
The patent utilizes parameter changes by making the sampling rate and evaluation criteria adjustable. The system can adapt its sampling rate (e.g., 100 kHz or 1 MHz) and evaluation parameters based on the specific welding process and measurement requirements, allowing a single system to optimize performance across different applications without requiring specialized hardware for each case.
2Measurement precision
If high sampling rates are used to capture instantaneous behavior during welding, then measurement precision is improved, but loss of energy and data processing burden increase
Solution Approach 1:
The patent applies extraction by selectively capturing only the critical instantaneous parameters needed for weld quality evaluation. Instead of continuously processing all possible data, the system extracts and evaluates specific parameters (welding current, voltage, load, displacement) at critical moments during the welding process, reducing overall data processing burden while maintaining measurement precision for key events.
Solution Approach 2:
The patent implements periodic action through controlled sampling at high rates during critical welding phases. The system uses periodic sampling at high rates (100 kHz or 1 MHz) specifically during the welding process when instantaneous behavior is critical, rather than continuous high-rate sampling throughout, thereby reducing energy consumption while capturing essential data.
3Reliability
If multiple specialized evaluation apparatuses are deployed for different measurement types, then measurement precision is improved, but device complexity and construction effort increase
Solution Approach 1:
The patent applies merging by combining multiple measurement functions into a single integrated evaluation system. Different physical quantity acquiring sections (for welding current, voltage, load, and displacement) are merged into one system that shares common analog-to-digital conversion and evaluation sections, achieving comprehensive weld quality assessment without requiring multiple separate specialized apparatuses.
Solution Approach 2:
The patent applies universality by designing the evaluation section to handle multiple types of input data from different measurement apparatuses through a unified processing architecture. The system can evaluate welding current, voltage, load, and displacement using the same evaluation logic and interface, eliminating the need for separate specialized evaluation apparatuses for each measurement type.
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 the construction of a cost-effective evaluation system capable of rapid nondestructive weld quality assessment, reducing the need for specialized apparatuses and facilitating real-time processing.
Implementation Method 1
an analog-to-digital converting section configured to convert an analog signal to a digital signal, the analog signal being acquired by a physical quantity acquiring section and indicative of a time-series change of at least one of (i) welding current, welding voltage, or load applied to pieces to be welded during welding and (ii) a displacement, during welding, of a welding head
Data Source
AI summary
Provided is an evaluation system including: an analog-to-digital converting section comprised of a programmable circuit and configured to convert an analog signal, the analog signal being acquired by a physical quantity acquiring section and indicative of a time-series change of at least one of (i) welding current, welding voltage, or load applied to pieces to be welded and (ii) a displacement, during welding, of a welding head; and an evaluating section configured to determine, based on a digital signal, whether or not the time-series change satisfies a predetermined condition, wherein configuration data for configuring the programmable circuit is arranged to be changeable by a user.