Weld Bead Inspection Gauge Using Visual Comparison
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Solution Overview
Problem
Current visual inspection methods for weld beads in production workshops are hindered by environmental conditions and operator skill, leading to low repeatability and precision due to the complexity and discomfort of mechanical dimensional measuring devices, resulting in unreliable inspection results.
Innovation Solution
A device comprising multiple gauges with different shapes, such as square, concave, rectangular, and straight edge designs, allows for the inspection of weld bead flaws without the need for precise measurements, simplifying the inspection process by directly comparing the flaw against welding quality standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mechanical dimensional measuring devices are used to measure weld bead flaws, then measurement capability is provided, but the complexity of the device and difficulty of operation increase, leading to low repeatability and precision
Solution Approach 1:
The patent replaces complex mechanical dimensional measuring devices with a simplified mechanical gauge system that uses direct visual comparison. Instead of requiring operators to use sophisticated measurement tools and perform calculations, the invention uses gauges with predefined acceptance criteria that can be directly applied to the weld bead for immediate visual assessment, eliminating the need for complex measurement and calculation procedures while maintaining measurement capability.
Solution Approach 2:
The patent changes the parameter representation from precise dimensional measurements requiring calculation to simplified visual comparison against predefined acceptance criteria. The gauges incorporate the acceptance criteria parameters directly into their physical design, allowing operators to assess compliance through direct visual inspection rather than measurement and calculation, thereby improving ease of operation while maintaining measurement precision.
2Reliability
If mechanical dimensional measuring devices are used to measure weld bead flaws, then measurement capability is provided, but the device complexity increases and the inspection process becomes time-consuming
Solution Approach 1:
The patent extracts the essential measurement and calculation functions from complex mechanical dimensional measuring devices and consolidates them into simple visual comparison gauges. By taking out only the necessary acceptance criteria and embedding them directly in the gauge design, the invention eliminates unnecessary device complexity while maintaining reliable inspection capability through direct visual assessment against predefined standards.
Solution Approach 2:
The patent creates simplified physical copies of the acceptance criteria in the form of gauges with predefined dimensions and features. Instead of requiring operators to use complex measurement devices and reference multiple standards, the invention provides direct physical copies of the acceptance criteria that can be visually compared against the weld bead, thereby reducing device complexity while ensuring reliable and consistent inspection results.
3Productivity
If visual inspection is performed in production workshop environmental conditions, then on-site inspection is enabled, but precision and repeatability decrease due to suboptimal environmental conditions
Solution Approach 1:
The patent segments the inspection function into simple, dedicated gauges for specific measurement tasks. By dividing the inspection process into discrete, purpose-built gauge components rather than requiring a single complex measurement device, the invention enables reliable on-site inspection in production workshop conditions. Each gauge is designed for a specific acceptance criterion, making the inspection process robust to environmental variations while maintaining precision.
Data Source
AI summary
Devices and methods comprise at least one gauge for inspecting weld seams comprising a plurality of cutouts: a square cutout, a rectangular cutout, a concave cutout with a protuberance; and a straight edge ending with a protruding part. The devices and methods make it possible to inspect the compliance of a weld bead with various quality standards, without taking measurements, or referring to said standards.