Automated Weld Inspection and Revision for Imperfect Weld Correction
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Solution Overview
Problem
Existing welding processes lack efficient and automated systems for inspecting and revising welds to ensure high-quality weld integrity, particularly in applications like battery support trays and vehicle bodies, where imperfect welds can compromise structural integrity.
Innovation Solution
A system comprising a weld inspection sensor, inspection controller, system controller, welding robot controller, and weld verification sensor to automatically inspect, designate imperfect welds for revision, and verify the revision process, using three-dimensional and two-dimensional cameras to assess weld parameters and guide robotic welding for correction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If automated inspection and revision systems are implemented, then weld quality and integrity are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The system divides weld inspection into multiple parameter measurements (weld length, width, height, position) using separate sensor arrays, and processes each parameter independently through dedicated algorithms before综合 evaluation. This segmentation allows comprehensive inspection while maintaining manageable system complexity through modular architecture.
Solution Approach 2:
A computer system with specialized algorithms acts as an intermediary between the sensor arrays and the welding revision process. The computer analyzes sensor data, identifies weld defects, and automatically controls the welding robot, eliminating the need for complex human judgment and manual intervention while maintaining system reliability.
2Productivity
If manual inspection and revision of welds is performed, then system complexity is reduced, but productivity and manufacturing efficiency decrease
Solution Approach 1:
The system performs self-inspection and self-correction by using sensor arrays to automatically detect weld defects and controlling welding robots to perform revision welding without human intervention. This automation maintains high productivity while managing complexity through integrated control algorithms.
Solution Approach 2:
The system continuously monitors weld parameters during the welding process using sensor arrays, compares actual measurements against target specifications, and automatically adjusts the welding process or triggers revision welding when defects are detected. This closed-loop feedback control maintains productivity by preventing defect accumulation and enabling immediate correction.
3Manufacturing precision
If comprehensive weld parameter inspection is performed, then weld quality is improved, but inspection time and production cycle lengthen
Solution Approach 1:
The system performs preliminary inspection of weld parameters immediately after welding using sensor arrays, identifying defects before the production line progresses further. This allows for immediate revision welding while the workpiece is still in position, minimizing the time added to the production cycle while maintaining comprehensive inspection quality.
Solution Approach 2:
The inspection process operates continuously during and immediately after the welding process without interrupting the production flow. Sensor arrays continuously monitor weld parameters in real-time, enabling immediate detection and correction of defects without stopping the production line, thus maintaining manufacturing precision while minimizing inspection time.
Data Source
AI summary
A system for inspecting and revising welds. The system includes: a weld inspection sensor configured to inspect weld parameters of the welds; an inspection controller configured to identify one or more of the welds as an imperfect weld based on the weld parameters; a system controller configured to designate the imperfect weld for revision based on the weld parameters of, and relative locations of, the welds that are proximate to the imperfect weld designated for revision; a welding robot controller configured to operate a welding robot to perform a revision weld at the imperfect weld; and a weld verification sensor configured identify a revision location of the revision weld. The system controller is configured to verify the revision weld based on the revision location identified by the weld verification sensor.