Weld Program Configuration System for Fatigue Reduction
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Solution Overview
Problem
High volume, complex welded assemblies produced using manual or semi-automated welders often suffer from welder fatigue, leading to missing or defective welds, which is a quality assurance issue. Existing methods rely on sensors to measure current, wire feed, voltage, and gas flow to identify defective welds but are inefficient in ensuring consistent quality.
Innovation Solution
The system designs a part weld process with a computing device that configures properties for visual representations of welds, allowing default values to be set and overridden at hierarchical levels, generating weld instructions and monitoring welding operations using sensors to detect events and update the process accordingly, thereby improving weld quality and reducing operator fatigue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual or semi-automated welders are used for high volume production, then productivity is improved, but weld quality reliability deteriorates due to welder fatigue
Solution Approach 1:
The system implements real-time feedback by monitoring welding parameters (current, voltage, wire feed, gas flow) during the welding process and comparing them against expected values. When deviations indicating potential defects are detected, the system immediately alerts the operator or automatically adjusts parameters, enabling continuous quality assurance without reducing production speed
Solution Approach 2:
The patent replaces manual visual inspection and operator judgment with automated sensor-based detection systems. Sensors continuously measure welding parameters and use processing logic to identify defective welds, eliminating the human element that causes fatigue-related quality issues while maintaining high production rates
2Measurement precision
If sensors are used to measure welding parameters for quality detection, then weld quality monitoring is improved, but device complexity increases
Solution Approach 1:
The system uses a multi-functional integrated controller that combines sensor data acquisition, parameter processing, defect detection logic, and output control in a single device. This universal controller handles multiple welding parameters (current, voltage, wire feed, gas flow) simultaneously, reducing the need for separate dedicated devices for each function and simplifying the overall system architecture
Solution Approach 2:
The patent transforms physical welding parameters (current, voltage, wire feed rate, gas flow) into standardized electrical signals that can be processed uniformly by the control system. By converting diverse physical measurements into a common signal format, the system simplifies data handling and comparison operations without losing measurement precision
3Ease of operation
If traditional weld program configuration methods are used, then ease of operation is maintained, but loss of time in configuring and modifying weld programs increases
Solution Approach 1:
The system includes pre-configured weld programs with default parameter sets and detection thresholds that are prepared in advance. When a new welding task begins, the operator can select from these pre-configured options and make minimal adjustments, rather than configuring all parameters from scratch. This preliminary preparation significantly reduces setup time while maintaining operational simplicity
Solution Approach 2:
The patent enables operators to copy existing weld programs and their associated parameter configurations to new programs. By duplicating proven working configurations and making necessary modifications, the system eliminates repetitive manual configuration work while preserving the simplicity of program setup and modification
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
This approach significantly reduces the time and effort required to configure and modify weld programs, enhances weld quality by providing real-time monitoring and feedback, and minimizes defective welds through automated detection and response to welding events, improving overall production efficiency.
Implementation Method 1
sensors that measure current, wire feed, voltage, and gas flow are used to enable the quality of a weld to be determined
Data Source
AI summary
Systems and methods to design part weld processes are disclosed. An example system to generate weld instructions for display to a weld operator during a welding sequence includes: a processor and machine readable instructions which cause the processor to: provide an interface to define a weld program including a sequence of weld instructions for display to a weld operator during a weld sequence, the weld program including a plurality of properties; determine, for each of the weld instructions, respective values for one or more properties that are defined via the interface; and generate the weld program including the sequence of weld instructions by, for each of the weld instructions in the sequence of weld instructions: determining default values for the properties that have not been defined for the weld instruction,; and generating a visual representation of the weld instruction using the defined values and using the determined default values.