Study of weld quality real-time monitoring system for auto-body assembly

Jun Xu; Yong-Bing Li; Guan-Long Chen

doi:10.1117/12.664355

20 February 2006 Study of weld quality real-time monitoring system for auto-body assembly

Jun Xu, Yong-Bing Li, Guan-Long Chen

Proceedings Volume 6041, ICMIT 2005: Information Systems and Signal Processing; 604120 (2006) https://doi.org/10.1117/12.664355
Event: ICMIT 2005: Merchatronics, MEMS, and Smart Materials, 2005, Chongqing, China

Abstract

Resistance spot welding (RSW) is widely used for the auto-body assembly in automotive industry. But RSW suffers from a major problem of inconsistent quality from weld to weld. The major problem is the complexity of the basic process that may involve material coatings, electrode force, electrode wear, fit up, etc. Therefore weld quality assurance is still a big challenge and goal. Electrode displacement has proved to be a particularly useful signal which correlates well with weld quality. This paper introduces a novel auto-body spot weld quality monitoring system which uses electrode displacement as the quality parameter. This system chooses the latest laser displacement sensor with high resolution to measure the real-time electrode displacement. It solves the interference problem of sensor mounting by designing special fixture, and can be successfully applied on the portable welding machine. It is capable of evaluating weld quality and making diagnosis of process variations such as surface asperities, shunting, worn electrode and weld expansion with real-time electrode displacement. As proved by application in the workshop, the monitoring system has good stability and reliability, and is qualified for monitoring weld quality in process.

Citation Download Citation

Jun Xu, Yong-Bing Li, and Guan-Long Chen "Study of weld quality real-time monitoring system for auto-body assembly", Proc. SPIE 6041, ICMIT 2005: Information Systems and Signal Processing, 604120 (20 February 2006); https://doi.org/10.1117/12.664355

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