Surface Flatness Evaluation for Consistent Weld Joint Quality
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Solution Overview
Problem
In mass-production manufacturing processes, such as plastic welding, variations in surface flatness of workpieces can lead to defective joints due to dimensional differences, reducing manufacturing efficiency and requiring rework or scrapping of assemblies.
Innovation Solution
A method is introduced to evaluate the flatness of a two-dimensional surface by measuring Z-axis coordinate data within a coordinate system, defining a best-fit plane, calculating a flatness value, and comparing it to a maximum allowable value to determine if the operation can proceed, ensuring that the operation is only performed when the surface flatness is within specified tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mass-production manufacturing processes are used to fabricate workpieces, then productivity is improved, but manufacturing precision deteriorates due to surface flatness variations
Solution Approach 1:
The patent applies preliminary action by measuring and evaluating surface flatness before the welding operation occurs. The system captures Z-axis coordinate data at multiple locations, calculates flatness values, and determines whether the surface meets acceptable criteria before proceeding with welding. This preventive approach allows for early detection of out-of-tolerance workpieces, preventing defective joints and reducing rework while maintaining mass-production efficiency
2Manufacturing precision
If surface flatness evaluation is performed at multiple locations, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical measurement systems with a scanner-based optical or electromagnetic measurement system. The scanner captures Z-axis coordinate data at multiple locations across the surface, and a processor automatically calculates flatness values by comparing coordinates to a best-fit plane. This substitution reduces mechanical complexity while improving measurement precision and enabling automated evaluation
Data Source
AI summary
A method of evaluating flatness of a two-dimensional area of a surface of an unfinished workpiece prior to performance of a process step in which a prescribed operation is performed on the surface by a tool. A flatness value for the surface is calculated and used either to allow or to disallow the prescribed operation to proceed, and when allowed, uses the flatness value for parameter adjustment.