Vibration Welding Quality Display via Status Projector
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Solution Overview
Problem
Vibration welding processes face challenges in consistently producing high-quality welds due to external factors and the need for laborious manual inspection, which can lead to premature failure of welds affecting the overall system performance.
Innovation Solution
A vibration welding monitoring system that includes a host machine, sensors, and a status projector to predict weld quality in real-time by processing sensory and control signals, allowing for the display of weld quality status on the work piece, thereby reducing manual inspection and identifying suspect welds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If closed-loop parameter-based control techniques are applied during vibration welding, then welding parameters consistency is improved, but weld quality reliability deteriorates due to external factors like material quality variations
Solution Approach 1:
The patent replaces manual mechanical picking inspection with an automated optical detection system using cameras and image processing algorithms to detect weld quality, thereby eliminating the limitations of human inspection while maintaining parameter control
Solution Approach 2:
The system implements real-time feedback by continuously monitoring welding parameters and material characteristics during the welding process, automatically adjusting control parameters to compensate for material variations and maintain weld quality consistency
2Measurement precision
If visual inspection and manual picking are used to determine weld integrity, then weld quality detection is possible, but productivity deteriorates due to laborious inspection processes
Solution Approach 1:
The patent replaces manual picking inspection with an automated optical detection system using cameras and image processing algorithms to detect weld quality, thereby eliminating the limitations of human inspection while maintaining detection accuracy
Solution Approach 2:
The system creates optical copies (images) of the welds and processes them digitally through image analysis algorithms, allowing for rapid automated assessment without physical contact or manual handling of each weld
3Reliability
If real-time weld quality monitoring is implemented, then false accepts are reduced, but device complexity increases due to additional sensors and processing systems
Solution Approach 1:
The system uses multi-functional sensors that simultaneously monitor multiple welding parameters (temperature, vibration, acoustic signals) and material characteristics, eliminating the need for separate dedicated sensors for each parameter and reducing overall system complexity
Solution Approach 2:
The patent combines the detection, analysis, and control functions into an integrated system where image processing and parameter analysis are merged into a unified quality assessment algorithm, reducing the complexity of separate processing subsystems
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
The system significantly reduces false accepts and minimizes the need for direct manual inspection, improving production efficiency by providing real-time weld quality assessment and highlighting suspect welds for targeted verification.
Implementation Method 1
high frequency vibration energy
Implementation Method 2
acoustic signals
Implementation Method 3
Surface friction generates heat at a weld interface
Implementation Method 4
high frequency vibration energy
Implementation Method 5
Surface friction generates heat
Implementation Method 6
activates the status projector to display the predicted quality status of the welds on or adjacent to the welds
Data Source
AI summary
A method includes receiving, during a vibration welding process, a set of sensory signals from a collection of sensors positioned with respect to a work piece during formation of a weld on or within the work piece. The method also includes receiving control signals from a welding controller during the process, with the control signals causing the welding horn to vibrate at a calibrated frequency, and processing the received sensory and control signals using a host machine. Additionally, the method includes displaying a predicted weld quality status on a surface of the work piece using a status projector. The method may include identifying and display a quality status of a suspect weld. The laser projector may project a laser beam directly onto or immediately adjacent to the suspect welds, e.g., as a red, green, blue laser or a gas laser having a switched color filter.