A research on quality monitoring system of spot welds with numerical simulator

数值模拟器点焊质量监控系统的研究

• 批准号: 08455335
• 负责人: ARAI Eiji
• 金额: $ 3.78万
• 依托单位: Osaka University
• 依托单位国家: 日本
• 项目类别: Grant-in-Aid for Scientific Research (B)
• 财政年份: 1996
• 资助国家: 日本
• 起止时间: 1996 至 1998
• 项目状态: 已结题
• 来源: https://kaken.nii.ac.jp/grant/KAKENHI-PROJECT-08455335/
• 关键词: Resistance welding; Quality monitoring; numerical simulation; Virtual welding machine; 抵抗スポット溶接

This research project is regarding to a developing high-speed quality monitoring system for resistance spot welds that cannot be observed directly during and after welding without destructive tests. The idea has been deduced from a concept that the invisible welding state (weld size, temperature fields etc.) would be indirectly estimated in a virtual welding machine made on computer memory by a numerical simulator if the non-linear phenomena like the welding phenomena could be described with some mathematical equations. Two wave forms of welding current and welding voltage have been measured for the input parameters to make input data for the simulator.The research project had been started in 1996. In the first year, some computer software to be run on a personal computer had been developed as implements for the numerical simulator. In the second year, 1997, high speed version of the simulator was developed to realize a real-time quality monitoring system that can be applied for resistance spot welding machines. And then, a personal computer system installed the high speed version was connected to a resistance spot welding machine in order to examine the possibility of the system. In the last year of 1998, the system performance to estimate the weld size has been evaluated with some destructive test results. Furthermore, a new total system installed the numerical simulator as the real-time quality monitoring system has been proposed, and assessed from point of view that the system will connect to other many welding and control systems trough the network lines.As a result, it is clarified that the real-time quality monitoring system has be realized with a improved algorism for the simulator based on the phenomenological modeling, and increasing the computing speed of new CPUs mounted in the personal computers.In addition, next target of the project is to realize a real-time control system of the weld quality with the high speed quality monitoring technique.

本研究项目是关于开发一个高速质量监测系统的电阻点焊，不能直接观察焊接过程中和焊接后，没有破坏性试验。这一思想是从一个概念推导出来的，即不可见的焊接状态（焊缝尺寸，温度场等）。如果像焊接现象这样的非线性现象可以用一些数学方程来描述，则可以通过数值模拟器在计算机存储器上制作的虚拟焊接机中间接估计。本课题于1996年开始研究，以焊接电流和焊接电压两种波形作为输入参数，作为模拟器的输入数据。在第一年，一些计算机软件运行在个人计算机上已开发的数值模拟器的实现。第二年，1997年，开发了模拟器的高速版本，以实现可应用于电阻点焊机的实时质量监控系统。然后，安装了高速版本的个人计算机系统连接到电阻点焊机，以检查该系统的可能性。在1998年的最后一年，系统的性能，估计焊缝尺寸已被评估与一些破坏性试验结果。提出了一种安装数值模拟器作为实时质量监控系统的新的整体系统，并从该系统将通过网络线路与其它多个焊接和控制系统连接的角度进行了评估，结果表明，基于唯象建模的数值模拟器改进算法实现了实时质量监控系统，本课题的下一个目标是利用高速质量监测技术实现焊接质量的实时控制系统。