System Development for In-Line and In-Process Measurement of Spot Weld Quality with Optical Measurement

使用光学测量在线和过程中测量点焊质量的系统开发

基本信息

  • 批准号:
    07555526
  • 负责人:
  • 金额:
    $ 2.94万
  • 依托单位:
  • 依托单位国家:
    日本
  • 项目类别:
    Grant-in-Aid for Scientific Research (A)
  • 财政年份:
    1995
  • 资助国家:
    日本
  • 起止时间:
    1995 至 1997
  • 项目状态:
    已结题

项目摘要

Resistance spot welding is widely used for the construction of thin sheet structures, and the weld quality is typically evaluated by the weld size as well as the strength, which are measured by various destructive methods. In recent automated processes, however, in-line or in-process inspection is demanded for the quality assurance of the spot welds, but there is few techniques applicable to the production line. In this study, therefore, optical measurement were tried to develop the in-line inspection and in-process monitoring for the fast evaluation of weld size and strength of spot welded structures, as follows.1.Nondestructive Evaluation of Spot Welds by Infrared ThermographyIn order to develop a in-line measuring system, infrared measurement were proposed for the nondestructive evaluation of weld quality and weld size. Since this measurement uses the thermal response to the heat input, heating method is important for the fast and large area inspection and the acquisition of the rea … More dily interpretable image of spot welded region. In this study, Joule effect heating due to the electric current flow through the back plate and across the welded region were used for the fast inspection. These heating methods also produced the readily interpretable images with high temperature at the boundary of welded region in the surface. The shape obtained from the maximum temperature position in the image indicated the welded area, and the evaluated size was in the accuracy of 0.3 mm. This method performed the measurement within 0.1 second, while the image processing requires for the measurement of weld size was 2.5 second. It is necessary to shorten the image processing time within 1 second, which is possible by use of high performance CPU.2.Nondestructive Evaluation of Spot Welds by Spectroscopic AnalysisIn order to develop a in-process measuring system, spectroscopic analysis was tried to monitor the weld quality during welding process. Two methods were used for the evaluation of weld size. First method is a measurement at the surface immediately after removal of electrode chip from specimen, and second one is a measurement with the fiber inserted in the electrode. Both measurement at the wave length 800 and 900 nm showed that spectrum intensity had a good relation with weld size, regardless of surrounding condition. However, this relation depended upon the plate thickness, materials and measuring time in the first method and upon the material in the second method. Therefore, second method is recommended for the in-process measurement, although the improvement is required in the electrode design, since the detecting hole in the electrode affects the appearance of spot welds.3.Prediction of Strength of Multi-Spot Welded StructuresIn addition to the weld size, the weld quality was also evaluated by the strength of welded structures. For this purpose, the prediction method was proposed for the strength of multi-spot welds. Since the strength of multi-spot welds depends upon the weld size, material properties, weld pitch, plate width and thickness, the relation between these factors and strength of single spot welds was clarified theoretically and experimentally. As a result, the theoretical stress analysis showed that the strength is given by the summation of fracture load of half sized single spot welded elements in the multi-spot welds. The estimated strength well agreed with the experimental results. This prediction enabled the in-line mad in-process assessments based upon both weld size and strength in the spot welded structures. Less
电阻点焊广泛用于薄板结构的构造,并且通常通过焊缝尺寸以及强度来评估焊缝质量,所述焊缝尺寸以及强度通过各种破坏性方法来测量。然而,在最近的自动化过程中,需要在线或过程中检测来保证点焊的质量,但是很少有适用于生产线的技术。因此,在本研究中,光学测量尝试发展在线检测和过程中监测的点焊结构的焊缝尺寸和强度的快速评估,如下。1.无损评价点焊通过红外热成像为了开发一个在线测量系统,红外测量提出了无损评价焊缝质量和焊缝尺寸。由于这种测量使用的是对热输入的热响应,因此加热方法对于快速和大面积的检测以及获得真实的热响应是很重要的。 ...更多信息 点焊区域的图像清晰易懂。在这项研究中,焦耳效应加热由于电流流过背板和整个焊接区域被用于快速检测。这些加热方法也产生了易于解释的图像,在表面的焊接区域的边界处的高温。从图像中的最高温度位置获得的形状表示焊接区域,并且评估尺寸的精度为0.3mm。该方法在0.1秒内进行测量,而焊接尺寸测量所需的图像处理为2.5秒。2.光谱分析法对点焊焊缝的无损检测为了研制一套在线检测系统,本文尝试用光谱分析法对焊接过程中的焊缝质量进行在线检测。两种方法用于焊缝尺寸的评价。第一种方法是在从样品中取出电极芯片后立即在表面进行测量,第二种方法是将纤维插入电极中进行测量。在波长800和900 nm处的测量表明,光谱强度与焊缝尺寸有很好的关系,无论周围的条件。然而,在第一种方法中,这种关系取决于板厚度、材料和测量时间,而在第二种方法中取决于材料。因此,建议采用第二种方法进行在线测量,但电极设计需要改进,因为电极上的检测孔会影响点焊的外观。3.多点焊结构强度的预测除了焊缝尺寸外,还通过焊接结构的强度来评估焊缝质量。为此,提出了多点焊缝强度的预测方法。由于多点焊缝的强度取决于焊缝尺寸、材料性能、焊缝间距、板宽和板厚,本文从理论和实验上阐明了这些因素与单点焊缝强度的关系。理论应力分析结果表明,多点焊缝的强度是由半尺寸单点焊接单元断裂载荷之和给出的。强度估算值与试验结果吻合较好。该预测使得能够基于点焊结构中的焊缝尺寸和强度进行在线和过程中评估。少

项目成果

期刊论文数量(18)
专著数量(0)
科研奖励数量(0)
会议论文数量(0)
专利数量(0)
里中 忍: "サーモグラフィ法を利用したスポット溶接部の品質評価" 溶接技術. 44. 84-90 (1996)
Shinobu Satonaka:“使用热成像技术评估点焊质量”《焊接技术》44. 84-90 (1996)。
  • DOI:
  • 发表时间:
  • 期刊:
  • 影响因子:
    0
  • 作者:
  • 通讯作者:
S.Satonaka, S.Arima, et al.: "Prediction of Strength of Multi-Spot Welds Based on Ultrasonic Testing" Proc.6th Int.Symp.of JWS. Vol.2. 815-820 (1996)
S.Satonaka、S.Arima 等人:“基于超声波测试的多点焊缝强度预测”Proc.6th Int.Symp.of JWS。
  • DOI:
  • 发表时间:
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  • 影响因子:
    0
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  • 通讯作者:
里中 忍: "スポット溶接の接合強度に及ぼす緒因子の評価" 溶接学会全国大会講演概要集第59集. 334-335 (1996)
里中忍:《点焊接头强度影响因素的评价》日本焊接学会全国会议讲座摘要第59卷334-335(1996年)
  • DOI:
  • 发表时间:
  • 期刊:
  • 影响因子:
    0
  • 作者:
  • 通讯作者:
里中 忍: "サーモグラフィ法を利用したスポット溶接部の品質評価" 溶接技術. 43・3. 84-90 (1996)
Shinobu Satonaka:“使用热成像的点焊质量评估”焊接技术 84-90 (1996)。
  • DOI:
  • 发表时间:
  • 期刊:
  • 影响因子:
    0
  • 作者:
  • 通讯作者:
S.SATONAKA,K.SHINOZAKI,K.TERADA,M.AKAMINE: "Ultrasonic Weld size and Strength of Spot Welds (in Japanese)" Proc.of Symp.on Welded Structures '95. 207-210 (1995)
S.SATONAKA、K.SHINOZAKI、K.TERADA、M.AKAMINE:“超声波焊接尺寸和点焊强度(日语)”Proc.of Symp.on Welded Structures 95。
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    0
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SATONAKA Shinobu其他文献

SATONAKA Shinobu的其他文献

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{{ truncateString('SATONAKA Shinobu', 18)}}的其他基金

Optimum Design of Spot Weld Joints and Nondestructive Measurement of Weld Quality for Light Weight Structures
轻质结构点焊接头优化设计及焊接质量无损测量
  • 批准号:
    11650133
  • 财政年份:
    1999
  • 资助金额:
    $ 2.94万
  • 项目类别:
    Grant-in-Aid for Scientific Research (C)
Development of In-Process Ultrasonic Measurement For Quality Assurance of Microjoints in Electronic Devices
用于电子设备微接头质量保证的过程中超声波测量的开发
  • 批准号:
    07650148
  • 财政年份:
    1995
  • 资助金额:
    $ 2.94万
  • 项目类别:
    Grant-in-Aid for Scientific Research (C)

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