Spot-Welding Electrode Micro-Array for Multi-Point Weld Monitoring
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Solution Overview
Problem
Existing resistance welding systems are limited in their ability to monitor weld quality outside of the center of the weld structure, resulting in poor structural performance due to inadequate information about weld parameters.
Innovation Solution
A spot-welding electrode assembly featuring a plurality of micro-elements positioned within the electrode or behind the electrode cap, which transmit and receive ultrasonic waves to provide comprehensive monitoring of weld quality across multiple points in the stack-up.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a large monolithic transducer is employed as both transmitter and receiver, then a strong signal-to-noise ratio is achieved, but measurement is limited to only the center of the weld
Solution Approach 1:
The patent divides a single large monolithic transducer into multiple smaller micro-elements arranged in an array. Each micro-element acts as an independent transmitter and receiver, enabling measurements at multiple locations across the weld while maintaining the signal-to-noise ratio benefits of focused ultrasonic transmission. This segmentation allows comprehensive monitoring of weld parameters throughout the entire weld structure, not just at the center.
2Device complexity
If a single center measurement point is used, then the measurement system is simple, but information about weld parameters outside the center is lost
Solution Approach 1:
The measurement system is segmented into multiple independent micro-elements distributed across the weld area. Each micro-element provides localized measurement data, and the collective data from all micro-elements creates a comprehensive picture of the entire weld structure. This approach maintains relative simplicity while dramatically improving information coverage.
Solution Approach 2:
The patent transitions from a single-point (0D/1D) measurement approach to a multi-point distributed measurement array that covers two-dimensional or three-dimensional weld volumes. This dimensional expansion allows simultaneous monitoring of multiple weld parameters across different spatial locations, providing comprehensive weld characterization without excessive complexity.
3Loss of information
If micro-elements are used instead of a monolithic transducer, then comprehensive weld monitoring is achieved, but the device complexity increases
Solution Approach 1:
Each micro-element in the array is designed to perform multiple functions: it can transmit ultrasonic waves, receive reflected waves, and independently process measurement data. This multi-functionality reduces the need for separate specialized components for each measurement task, thereby managing overall system complexity while achieving comprehensive weld monitoring capability.
Solution Approach 2:
The micro-elements are designed to be self-contained units that can independently transmit and receive ultrasonic signals. Each element serves itself by generating its own measurement data without requiring complex external coordination, reducing the overall system complexity while enabling comprehensive multi-point monitoring of weld parameters.
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 enables simultaneous monitoring of weld formation across multiple points, providing real-time data on weld geometry and quality, thereby improving the structural integrity of the weld.
Implementation Method 1
transmitting an ultrasonic wave from a plurality of sources in the electrode to a plurality of spaced-apart points in the stack-up
Implementation Method 2
monitoring the ultrasonic wave after it encounters boundaries in the stack-up
Implementation Method 3
The concave inner surface of the electrode cap may be configured to act as a lens for the ultrasonic waves generated by the micro-elements
Implementation Method 4
The inner surface of the electrode cap may be configured to focus the wave from each of the micro-elements to a point within a work area adjacent an outer surface of the electrode cap
Implementation Method 5
As the electrical current passes through the material, it generates heat through joule heating, which results in softening and eventually melting of the metal
Data Source
AI summary
A spot-welding electrode assembly includes an electrode, an electrode cap at an outer end of the electrode, and a plurality of transducer elements positioned inward of the electrode cap. The transducer elements may be micro-elements. A method for monitoring a weld formed by a spot-welder includes passing current from an electrode assembly through a stack-up, transmitting an ultrasonic wave from each of a plurality of sources in the electrode assembly to a plurality of points in the stack-up, and monitoring the ultrasonic waves to monitor the weld formation.