Weld Seam Geometry Encoding for Embedded Process Data
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Solution Overview
Problem
Existing welding processes lack a reliable method for long-term storage and retrieval of information about the welding parameters and process data, leading to potential loss of critical information during inspection and quality control.
Innovation Solution
Incorporating information into the weld seam by varying control parameters to alter detectable external physical properties, allowing this information to be stored and read out later using a sequence of measurable geometric parameters, such as weld seam thickness or length, in the form of a machine-readable digital code.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If welding process data is stored in paper form or on computer at the welding location, then information is preserved during welding, but information is unavailable or inaccessible during inspection
Solution Approach 1:
The patent merges the welding information storage function with the weld seam structure itself. By encoding welding parameters (current, voltage, speed, etc.) into the physical geometry of the weld seam through controlled variations during welding, the information becomes permanently embedded in the welded joint. This eliminates the need for separate paper or computer documentation, making the information both preserved and accessible during inspection through direct measurement of the weld seam properties.
2Loss of information
If control parameters are varied to encode information in the weld seam, then information storage capability is improved, but manufacturing precision of the weld seam is compromised
Solution Approach 1:
The patent applies local quality by introducing information-carrying variations only in specific localized regions of the weld seam, rather than throughout the entire weld. By encoding information in discrete segments or markers within the weld geometry, the overall structural integrity and precision of the weld seam are maintained while still embedding the necessary process data in specific locations where controlled geometric variations are introduced.
3Ease of operation
If additional documentation systems are used to store welding information, then information accessibility is improved, but device complexity increases
Solution Approach 1:
The patent implements self-service by making the weld seam itself the storage medium for welding information. The weld seam's geometric properties automatically encode the welding parameters, eliminating the need for external documentation systems. During inspection, the weld seam's own physical characteristics are measured to retrieve the stored information, making the system self-contained and reducing overall complexity.
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 permanent and easily accessible storage of welding process data and parameters directly within the weld seam, facilitating efficient quality control and inspection without the need for additional documentation.
Implementation Method 1
The filler material and the components are at least partially melted by applying energy
Implementation Method 2
at least one control parameter of the control unit influences a detectable external physical weld seam property of the weld seam
Data Source
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AI summary
In order to facilitate the availability of information on a welding method being carried out, the invention proposes a welding method for bonding at least two components (5) using at least one additive material (Z). A welding seam (N) consisting of the additive material (Z) is produced with a specified course between a seam start and a seam end, wherein the process of producing the welding seam (N) is controlled using at least one control unit (4), at least one detectable external physical welding seam property of the welding seam (N) is influenced by at least one control parameter of the control unit (4), and information is taken into consideration for the at least one control parameter, said information being stored during the process of producing the welding seam (N) between an information start point (ISP) and an information end point (IEP) in the course of the seam using the at least one detectable external physical welding seam property in the welding seam (N) so that the information can be read, preferably optically and/or haptically, from a sequence of the at least one detectable external physical welding seam property along the course of the seam in the region between the information start point (ISP) and the information end point (IEP).