Welding Monitoring Using Local Current and Temperature Comparison
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Solution Overview
Problem
Existing welding monitoring systems, such as those described in Patent Literature 1, fail to adequately address non-uniform welding or the presence of foreign particles in the welded part, leading to quality control issues despite the use of appropriate welding members and conditions.
Innovation Solution
A welding monitoring system that includes a current measuring unit, a temperature measuring unit, and a determination unit to assess local current and temperature information, comparing it with past data to identify abnormalities, thereby improving quality control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding monitoring is performed using only predetermined welding condition checks, then manufacturing efficiency is maintained, but welding quality cannot be ensured when non-uniform welding or foreign particles are present
Solution Approach 1:
The monitoring system is segmented into multiple independent measurement units (current measuring unit, temperature measuring unit) that each perform specific functions. This allows the system to detect various welding abnormalities through specialized sensors rather than requiring a single complex monitoring mechanism, thereby improving reliability while managing device complexity.
Solution Approach 2:
The determination unit acts as an intermediary that receives data from multiple measurement units and compares it against stored reference information. This intermediary component integrates information from different sources to make the final quality assessment, enabling comprehensive welding quality monitoring without requiring direct complex interaction between all measurement components.
2Reliability
If local current and temperature measurements are performed during welding, then welding abnormalities can be detected, but measurement precision requirements increase
Solution Approach 1:
The system implements feedback by storing reference current and temperature information from normal welding operations and comparing real-time measurements against these references. The determination unit uses this feedback mechanism to identify abnormalities, allowing the system to achieve reliable detection without requiring extremely high absolute measurement precision, as it relies on detecting deviations from established norms rather than absolute precision.
3Reliability
If comprehensive welding monitoring is implemented, then quality control improves, but processing time increases
Solution Approach 1:
The current and temperature measurements are performed continuously during the welding process rather than requiring separate inspection steps. This continuous monitoring approach allows quality control to be integrated into the welding operation itself, eliminating additional processing time while maintaining comprehensive quality oversight through real-time data collection and comparison.
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
Enhances quality control by detecting and addressing non-uniform welding and foreign particles, ensuring consistent and high-quality welding processes.
Implementation Method 1
The principle of resistance welding is that a current is applied to a member, and a welded part is heated utilizing Joule heat generated by electric resistance of metal
Implementation Method 2
a welded part is heated utilizing Joule heat generated by electric resistance of metal
Data Source
AI summary
To improve quality control of welding, there is included in resistance welding: a magnetic field measuring unit (205) disposed around a welded part and configured to measure a local current at the welded part; a high-speed camera (202) configured to capture an image for measuring local temperature at the welded part from variation of luminance of emission by capturing light emission state of the welded part; a comparison determination unit (106) configured to determine whether or not at least one of current information and temperature information has an abnormal value by comparing the current information calculated based on magnetic field information acquired from the magnetic field measuring unit with past current information and comparing the temperature information measured from an image of the high-speed camera (202) with past temperature information.