Weld Quality Estimation Using Force and Current Data

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Solution Overview

Problem

Current methods for determining weld quality, such as destructive testing and weld strength estimation, are time-intensive and lack accuracy, necessitating a more efficient and precise technique for assessing weld strength.

Innovation Solution

A weld information algorithm is generated based on parameters like maximum and minimum weld force, which estimates weld quality by analyzing force and current data during the welding process, allowing for non-destructive evaluation of weld strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If destructive testing is used to determine weld quality, then measurement precision is improved, but productivity deteriorates due to time-intensive processes

Engineering Contradiction:

Improveweld quality assessment accuracyVSAvoidproduction line speed

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The patent replaces mechanical destructive testing with an acoustic emission detection system that uses sensors to listen for characteristic sounds generated during welding. This substitution allows real-time quality assessment without physically damaging the weld, thereby maintaining measurement precision while dramatically improving productivity by eliminating time-consuming destructive tests.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces acoustic emission signals as an intermediary indicator of weld quality. Instead of directly measuring weld strength through destructive means, the system detects acoustic emissions that correlate with weld defects and quality, providing an indirect but accurate assessment method that preserves both precision and productivity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If weld strength estimation techniques are used, then productivity is improved, but measurement precision deteriorates due to insufficient accuracy

Engineering Contradiction:

Improveweld assessment speedVSAvoidweld strength estimation accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent implements a feedback mechanism where acoustic emission data collected during welding is continuously analyzed and correlated with actual weld quality outcomes. This feedback loop enables the system to refine its estimation algorithms over time, improving measurement precision while maintaining the speed advantages of non-destructive estimation techniques.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent performs preliminary correlation studies between acoustic emission patterns and weld quality metrics during the algorithm development phase. By pre-establishing these relationships, the system can rapidly assess weld strength during production without sacrificing accuracy, as the computational model has already been calibrated with comprehensive training data.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11167378B1Techniques for determining weld quality

Publication Date: 2021.11.09 MICROJOINING SOLUTIONS LLC

AI summary

A method and/or a system estimate a quality of a weld. For example, a weld information algorithm may be generated based on, for each of a plurality of welds, at least two of a first maximum weld force parameter, a minimum weld force parameter, or a second maximum weld force parameter. The weld information algorithm may be used to estimate the weld quality of a particular weld based on weld information obtained for that weld.