Weld Bead Inspection Mask with Tolerance Markers
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Solution Overview
Problem
Current methods for inspecting weld beads on complex automobile components, such as motor vehicle cradles, are unreliable, time-consuming, and prone to operator interpretation errors, especially when dealing with complex shapes and multiple weld beads distributed on curved surfaces.
Innovation Solution
A customizable inspection mask with adapted shapes and visual markers that allows precise positioning and viewing of weld beads, featuring elongated openings and color markings indicating tolerance limits, enabling quick and objective assessment of weld bead conformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If an operator visually compares the cradle with a model to check weld beads, then the inspection can be performed with simple equipment, but the inspection time is relatively long and reliability is reduced
Solution Approach 1:
The patent creates a physical mask that is a simplified copy of the reference model, containing only the critical weld bead positions and tolerance zones. This mask serves as a portable reference tool that operators can use directly on the assembly, eliminating the need for complex imaging equipment while maintaining inspection accuracy and significantly reducing inspection time.
2Device complexity
If an operator visually compares the cradle with a model to check weld beads, then the equipment remains simple, but the operator must be qualified and interpretation errors occur
Solution Approach 1:
The mask incorporates local quality by including only the specific critical areas (weld bead positions and tolerance zones) rather than the entire assembly. Each opening in the mask corresponds to a specific weld bead location with marked tolerance limits, providing localized reference information that eliminates operator interpretation errors and ensures consistent inspection criteria.
3Measurement precision
If a camera with laser source is used to visualize and automatically analyze weld beads, then measurement precision is improved, but the installation becomes complex and costly
Solution Approach 1:
The patent employs a simple, inexpensive physical mask that can be easily manufactured and replaced if needed. This disposable-like approach replaces complex, expensive camera and laser systems with a simple optical aid that achieves the same measurement precision through clever design of openings and tolerance markers visible to the naked eye.
4Extent of automation
If a camera system is used for weld bead inspection, then automatic analysis is achieved, but the method is difficult to generalize for complex shapes
Solution Approach 1:
The mask design achieves universality by being adaptable to different cradle configurations. The mask can be customized with different patterns of openings and tolerance markers to match various weld bead arrangements on complex shapes, making it applicable to multiple assembly types while maintaining simplicity. The mask serves multiple inspection functions through its geometric design.
Data Source
Figure 1~5
AI summary
The invention relates to a mask for checking weld beads of an assembly (2) consisting of a stamped and punched metal sheets attached together by weld beads, characterized in that it includes forms adapted to be precisely positioned on the assembly (2) and to closely cover said assembly at least at the weld beads to be checked, and in that it comprises openings (8) for observing the weld beads through the mask (1), as well as visual reference marks (22, 24) for checking the edges of the weld beads, said reference marks defining tolerances and being arranged near said openings.