Force-based weld quality monitoring algorithm. (26th January 2011)

• Record Type: Journal Article
• Authors: El-Banna, Mahmoud; Filev, Dimitar; Tseng, Finn
• Is Part Of: International journal of intelligent systems technologies and applications. Volume 10:Number 1(2011)
• Page Start: 1
• Page End: 14
• Publication Date: 2011-01-26
• Subjects: nondestructive testing -- NDT -- online monitoring -- indirect estimation -- resistance spot welding -- force sensors -- soft sensors -- medium frequency -- direct current -- constant current -- weld quality -- weld defects -- expulsion welds -- cold welds -- quality monitoring -- weld monitoring; Artificial intelligence -- Periodicals; Intelligent control systems -- Periodicals; 006.3
• Languages: English
• ISSNs: 1740-8865

Abstract

Traditionally, to check weld quality, destructive (the dominant method at industry until now) and non-destructive tests are used on randomly sampled work pieces at the production site. These processes tend to be predominantly off-line or end-of-line processes. The objective of the force-based weld monitoring algorithm is to classify the weld status, i.e. cold, normal and expulsion, by using non-intrusive force sensor. It is composed mainly from two sub-algorithms: expulsion and normal welds detection. This algorithm has been tested on medium frequency direct current (MFDC) constant current (CC) control. The results were as follows: the percentage of the false alarm (I) type-1 error is the lowest for cold welds case at 3.6%, 11.0% for normal welds and 21.7% for expulsion welds. As for the failed alarm (β) type-2 error, the lowest percentage is for expulsion welds 1.9%, 3.4% for cold welds and 16.5% for normal welds.