Sensorized Hammer Testing for Non-Destructive Weld Fault Detection
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Solution Overview
Problem
Conventional methods for detecting welding faults in vehicle parts, such as visual inspection and cutting inspection, are inadequate as they either fail to identify welding depth or misalignment and require destruction of parts for sampling inspection, limiting their applicability for total inspection.
Innovation Solution
A fault detection apparatus utilizing a hammer device with a force sensor and vibration sensor to apply and measure forces, calculate frequency response functions, and determine faultiness based on peak values in predetermined regions, enabling non-destructive total inspection of welding parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If visual inspection method is used, then total inspection can be performed, but welding depth and misalignment cannot be identified
Solution Approach 1:
The patent replaces visual inspection with mechanical impact testing. A hammer applies controlled impact forces to the welded workpiece, and sensors detect the resulting vibrations and acoustic emissions. This mechanical testing method enables both total inspection coverage and precise detection of welding defects including depth and misalignment that are invisible to visual inspection.
Solution Approach 2:
The patent introduces sensors as intermediary devices between the hammer impact and the inspection result. These sensors capture vibration signals and acoustic emissions generated during impact, serving as mediators that translate mechanical responses into detectable data for identifying welding defects such as insufficient penetration and misalignment.
2Measurement precision
If cutting inspection method is used, then welding fault can be accurately determined, but total inspection cannot be performed due to part destruction
Solution Approach 1:
The patent replaces destructive cutting inspection with non-destructive mechanical impact testing. By analyzing vibration characteristics and acoustic emissions from hammer impacts, the system can accurately identify welding faults without cutting or damaging the workpiece, thereby enabling inspection of 100% of produced parts rather than only sampled portions.
Solution Approach 2:
The workpiece itself serves as the testing medium - its natural vibration response to hammer impact reveals its structural integrity and welding quality. No external destructive action is needed; the workpiece's own mechanical behavior under controlled impact provides the inspection data, eliminating the need for cutting or sampling.
3Device complexity
If conventional inspection methods are used, then simple equipment can be employed, but comprehensive fault detection is not achieved
Solution Approach 1:
The patent creates a multi-functional inspection system where a single hammer device with integrated sensors serves multiple detection purposes. The same impact mechanism and sensor system detect various welding defects including cracks, insufficient penetration, misalignment, and other faults, replacing multiple specialized inspection methods with one universal device.
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 accurate and comprehensive inspection of welding parts by comparing frequency response functions, allowing for quick identification of faults without damaging the parts, thus overcoming the limitations of existing methods.
Implementation Method 1
an elastic body provided on the upper body
Implementation Method 2
The support may be formed of an elastic material to absorb vibration of the hammer and the elastic body
Data Source
AI summary
An embodiment hammer device includes a driver, an upper body configured to move in a direction set by power generated from the driver, an elastic body provided on the upper body, a hammer provided in the elastic body, a force sensor provided in the hammer, and a support configured to support the elastic body and the hammer.