Torch-Mounted AE Sensing for Multi-Zone Welding Monitoring
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Solution Overview
Problem
Existing welding technologies face challenges in accurately monitoring the welding conditions of individual weld zones when multiple parts are welded simultaneously due to the mixing and superimposition of acoustic emissions (AE waves) generated at different zones, making it difficult to determine the quality of each zone independently.
Innovation Solution
A welding apparatus with multiple welding machines and sensors installed on each torch member to detect and process AE waves separately for each weld zone, using piezoelectric elements and processing circuits to distinguish and determine the welding conditions of individual zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single AE sensor is installed on the weld object to detect AE waves, then the welding condition can be monitored, but when multiple parts are welded simultaneously the AE waves from different zones are mixed and superimposed, making it impossible to accurately monitor individual weld zones
Solution Approach 1:
The invention divides the monitoring system into multiple independent sensor units, each attached to a separate torch member. Each sensor unit independently monitors AE waves from its corresponding weld zone, preventing signal mixing. This segmentation allows simultaneous monitoring of multiple weld zones without interference, resolving the contradiction between monitoring accuracy and system complexity.
2Reliability
If AE sensors are installed on the weld object side to detect AE waves, then welding monitoring is achieved, but the detection signals from multiple weld zones are superimposed and cannot be differentiated
Solution Approach 1:
The torch member serves as an intermediary medium between the weld zone and the AE sensor. AE waves generated at the weld zone are transmitted through the torch member to the sensor, which is attached to the torch member's proximal end. This intermediary approach allows each sensor to capture only the AE waves from its associated weld zone, preventing information mixing and enabling reliable individual zone assessment.
3Measurement precision
If multiple AE sensors are installed on the weld object to monitor multiple weld zones independently, then individual zone monitoring is achieved, but the device complexity and cost increase significantly
Solution Approach 1:
Each torch member is equipped with an AE sensor, making the torch member itself a multi-functional component that both performs welding and enables independent monitoring of its weld zone. This universal approach integrates monitoring capability into the existing welding equipment without requiring separate sensor installation systems on the weld object, thereby achieving individual zone precision while controlling overall system complexity.
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 monitoring and differentiation of welding conditions for each weld zone, ensuring reliable quality assessment even during simultaneous welding of multiple parts on a single object.
Implementation Method 1
a first sensor installed on the installation surface of the first torch member and configured to detect an elastic wave transmitted to the first torch member
Data Source
AI summary
According to one embodiment, a welding apparatus includes a first welding machine including a first torch member formed of a metallic material to weld a first weld zone of a weld object, a second welding machine including a second torch member formed of a metallic material to weld a second weld zone of the weld object, a first sensor installed on the first torch member to detect an elastic wave transmitted to the first torch member, a second sensor installed on the second torch member to detect an elastic wave transmitted to the second torch member, and first and second processing circuits determining a welding condition of the first weld zone and the second weld zone based on a detection signal from the first sensor and the second sensor.