Welding Motion Data Analysis for Objective Quality Control
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Solution Overview
Problem
Current welding quality control methods are inadequate in accurately measuring and replicating the tacit knowledge of skilled technicians, leading to inefficiencies in training and potential losses of skilled techniques due to variability in welding motions and lack of objective evaluation.
Innovation Solution
A welding work data accumulation device that measures and analyzes welding motions and phenomena, extracting feature amounts to create a database for recording and correlating welding quality parameters, allowing for the derivation of exemplary motions and correction instructions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If skilled technicians directly instruct unskilled operators through observation and imitation, then skill transfer can occur, but the instruction is imprecise and time-consuming due to tacit knowledge being difficult to quantify
Solution Approach 1:
The patent replaces the mechanical observation-imitation training method with an automated measurement and analysis system. Motion measurement devices, welding environment measurement devices, and arithmetic processing devices objectively capture and analyze welding motions and environments, converting tacit knowledge into quantifiable data that can be precisely instructed to unskilled operators.
Solution Approach 2:
The patent introduces measurement devices and arithmetic processing devices as intermediaries between skilled technicians and unskilled operators. These devices objectively measure and analyze welding motions and environments, serving as a mediator that translates tacit knowledge into explicit, quantifiable data for precise skill instruction.
2Measurement precision
If measurement devices are used to datafy welding work, then objective evaluation becomes possible, but welding quality control cannot be appropriately performed due to inability to capture tacit knowledge nuances
Solution Approach 1:
The patent creates a comprehensive measurement system that simultaneously measures multiple aspects of welding work: motion measurement devices capture welding motions, welding environment measurement devices measure welding environments, and arithmetic processing devices analyze both. This multi-functional approach ensures both objective measurement and reliable quality control by capturing the full context of welding work.
Solution Approach 2:
The patent implements feedback mechanisms where measurement data is analyzed and used to provide guidance to operators. The arithmetic processing device compares measured data with reference data and provides feedback on welding quality, enabling both objective evaluation and reliable quality control through continuous monitoring and correction.
Data Source
AI summary
An object of the present invention is to appropriately perform a welding quality control. Therefore, a welding work data accumulation device (100) includes: a measurement unit (4, 5, 7, 9, 11, and 16) that measures a welding motion and a welding phenomenon when a welding operator (1) grips a welding torch (2) and performs welding on a welded body (3); a data analysis unit (14) that extracts an appropriate combination of a welding motion feature amount (Tw, Ht, and Sp) and a welding phenomenon feature amount (Iw, S, and Ssym) in correction with time or coordinates based on data acquired by the measurement unit (4, 5, 7, 9, 11, and 16); and a data accumulation unit (15) that creates a database (70) based on an extraction result of the data analysis unit (14).