Weld Bead Profile Monitoring for Real-Time Fault Prediction
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Solution Overview
Problem
Existing methods for detecting welding faults in multilayer manufacturing objects require time-consuming and destructive inspections, making it difficult to evaluate fault size and impact on quality, and there is a need for real-time fault prediction and prevention during the welding process.
Innovation Solution
A fault-monitoring device and method that predicts welding faults by analyzing the shape profiles and feature amounts of existing weld beads, identifying potential fault locations, and providing real-time feedback to adjust the welding process to prevent faults.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If non-destructive inspection methods such as ultrasonic search are used to detect faults, then the structure can be inspected without damage, but it is difficult to sufficiently evaluate the fault size in structures having complicated shapes
Solution Approach 1:
The patent creates a virtual copy of the weld bead geometry through 3D scanning and point cloud processing. This digital replica allows for precise measurement and evaluation of fault sizes in complicated structures without the limitations of physical inspection methods. The virtual model enables accurate dimensioning of cavities and defects regardless of the structure's geometric complexity.
Solution Approach 2:
The patent replaces traditional mechanical ultrasonic inspection methods with an optical scanning system that uses light to create 3D surface profiles. This substitution enables precise measurement of fault dimensions in complicated geometries where ultrasonic methods struggle, transforming the inspection approach from contact-based acoustic waves to non-contact optical measurement.
2Reliability
If the entire line of the weld bead is inspected by non-destructive inspection after welding, then faults such as unwelded portions can be confirmed, but it requires time and effort and is not realistic
Solution Approach 1:
The patent performs 3D scanning and fault analysis during or immediately after the welding process itself, rather than scheduling a separate post-welding inspection. By capturing the weld bead geometry while it is still hot or shortly after solidification, the system enables real-time or near-real-time fault detection, dramatically reducing the time loss associated with traditional post-inspection methods.
Solution Approach 2:
The patent establishes a continuous monitoring system where the weld bead is scanned and analyzed continuously as it is being formed or immediately after formation. This continuous action eliminates the discontinuous nature of traditional inspection methods, maintaining constant surveillance of the welding process to detect faults without interrupting production flow.
3Reliability
If cutting the welded structure is performed to confirm faults, then the fault can be directly observed, but it takes much time and effort to recover the structure as a product
Solution Approach 1:
The patent creates a detailed digital replica of the weld bead's three-dimensional geometry through scanning and point cloud processing. This virtual copy allows for direct observation and measurement of faults such as cavities and unwelded portions without physically cutting into the structure, thereby preserving the product's integrity and eliminating recovery time while maintaining accurate fault detection.
4Productivity
If welding is continued without evaluating fault influence on quality, then productivity is maintained, but quality may be compromised
Solution Approach 1:
The patent implements a feedback system where the 3D scanned geometry of the weld bead is automatically analyzed to detect faults and evaluate their influence on quality. This feedback information is then used to determine whether welding should continue or be adjusted, enabling informed decisions that maintain both productivity and quality by avoiding unnecessary interruptions while preventing quality compromise.
Data Source
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AI summary
A fault-monitoring device includes: a shape profile acquisition unit that acquires a shape profile of the existing weld bead; a feature amount extraction unit that extracts a feature amount of a concave shape formed by the plurality of existing weld beads included in the shape profile; a fault position identification unit that identifies a fault candidate location where the welding fault is expected to occur according to the extracted feature amount; and a control unit that causes the shape profile acquisition unit to update the shape profile when the welding device newly forms the weld bead and repeatedly executes the extraction of the feature amount by the feature amount extraction unit and the identification of the fault candidate location by the fault position identification unit.