Welded Component Seam Inspection Using Edge Markers
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Solution Overview
Problem
Current methods for assessing weld seam quality are time-consuming and require destructive testing, making it difficult to detect and correct systematic errors in weld seam position during the manufacturing process, leading to rejected production batches.
Innovation Solution
The method involves creating optical markers parallel to the trimming edges of component sections, allowing for immediate visual inspection and assessment of weld seam position relative to the markers, enabling prompt detection of errors and correction during the manufacturing process without destructive testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If destructive testing methods (microsection evaluation) are used to assess weld seam quality, then measurement precision is improved, but loss of time increases and productivity decreases
Solution Approach 1:
Markers are created on the component surfaces before welding takes place. These markers serve as reference points that enable immediate visual assessment of weld seam position after welding, eliminating the need for time-consuming post-weld microsection preparation and evaluation.
Solution Approach 2:
The patent replaces destructive mechanical testing (microsection preparation, mounting, polishing, and microscopic examination) with a simple visual inspection method using optical markers. This substitution dramatically reduces assessment time while maintaining adequate measurement precision for weld position control.
2Measurement precision
If destructive testing methods are used to evaluate weld quality, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent extracts the essential measurement function from complex destructive testing equipment and simplifies it to basic visual inspection using markers. By creating visible reference points on the component surfaces, the complex task of weld quality assessment is reduced to comparing marker positions with weld seam positions, eliminating the need for microscopes, sectioning equipment, and specialized testing apparatus.
Solution Approach 2:
The markers used in this method are simple, inexpensive features created directly on the component surfaces. They serve their purpose for quality assessment and can be ignored afterward, replacing the need for expensive, complex testing equipment while providing sufficient measurement capability for process control.
3Productivity
If systematic errors in weld seam position occur, then productivity is maintained, but reliability decreases due to undetected defects
Solution Approach 1:
The markers provide immediate visual feedback on weld seam position relative to the component geometry. Operators can quickly identify systematic positioning errors by observing marker-weld relationships, allowing for real-time correction of welding parameters or tool positioning to maintain consistent quality throughout production batches.
Solution Approach 2:
By pre-positioning markers on the components before welding, the system establishes reference points that enable immediate detection of position errors. This preliminary setup allows for quick identification and correction of systematic errors during production, maintaining both productivity and reliability.
Data Source
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AI summary
In the production of welded components 1, a first component section 7 with a first trim edge 8 and a second component section 9 with a second trim edge 10 are produced. The first trim edge 8 and the second trim edge 10 are positioned relative to each other, and the first component section 7 and the second component section 9 are joined by means of a weld seam 16. According to the invention, before the weld seam 16 is produced, particularly during sheet metal cutting, several markers 11, 12 are created parallel to the first trim edge 8 and/or parallel to the second trim edge 10 at a distance x from the trim edge 8, 10. During or after the weld seam 16 is produced, the position of the weld seam 16 is checked by evaluating the position of the markers 11, 12 relative to the weld seam 16.