Weld Point Gap Detection Using Force-Displacement Slope Analysis
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Solution Overview
Problem
Current welding quality detection methods are time-consuming, labor-intensive, and lack accuracy, especially for detecting weld points in battery modules, as they rely on manual inspection and are not stable across various environments.
Innovation Solution
A welding quality detection system and method that applies a force to weld points between two welded objects and uses a displacement detector to analyze the slope of a displacement signal to determine if a gap exists, allowing for quick and precise assessment of welding quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual detection is used to check weld points, then labor flexibility is maintained, but detection accuracy and stability deteriorate
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated detection system that applies force through a probe and measures displacement signals. This substitution eliminates human error and inconsistency while maintaining operational flexibility through programmable force parameters and automated judgment criteria.
Solution Approach 2:
The patent transforms the detection process by changing multiple parameters: applying controlled force parameters, measuring displacement parameters, calculating slope parameters, and comparing against threshold parameters. This multi-parameter approach enables precise, repeatable detection that overcomes the limitations of manual inspection.
2Difficulty of detecting and measuring
If geometric detection, resistance detection or temperature detection is used, then detection capability is enhanced, but stability and environmental adaptability deteriorate
Solution Approach 1:
The patent replaces unstable geometric, resistance, or temperature detection methods with a mechanical force-displacement detection system. By measuring the displacement response to applied force, the system achieves stable detection that is not affected by environmental conditions, while maintaining high detection capability through slope analysis.
3Measurement precision
If all weld points are detected individually, then detection completeness is improved, but productivity deteriorates
Solution Approach 1:
The patent implements preliminary action by pre-setting force parameters, displacement thresholds, and judgment criteria before detection begins. This allows the system to quickly evaluate each weld point using predetermined standards, enabling complete detection of all weld points without sacrificing production speed.
Solution Approach 2:
The patent uses parameter changes to enable rapid detection: applying standardized force parameters, measuring displacement parameters in real-time, calculating slope parameters automatically, and comparing against threshold parameters. This standardized parameter approach allows quick evaluation of each weld point while maintaining detection completeness.
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
Enables rapid and accurate detection of welding quality by quantizing force, time, displacement, and slope, improving stability and enabling real-time detection of both solid and false weld points, facilitating efficient supplemental welding processes.
Implementation Method 1
a detection device configured for applying a force to at least one weld point of one of a first welded object and a second welded object that are welded together; a displacement detector configured for detecting a displacement signal that varies with the force or time between the first welded object and the second welded object based on the force applied to the weld point by the detection device
Data Source
AI summary
A welding quality detection system and a welding quality detection method are provided. A detection device applies a force to at least one weld point of a first welded object or a second welded object that are welded together. A displacement detector detects a displacement signal that varies with the force or time between the first welded object and the second welded object based on the force. A detection module receives or records the displacement signal and determines whether a gap exists between the first welded object and the second welded object based on a slope of the displacement signal, so as to detect the welding quality of the weld point quickly and precisely.