Image-based electrode tip displacement in resistance spot welding

Simončič, Samo; Podržaj, Primož

doi:10.1088/0957-0233/23/6/065401

Cited by 35 publications

(17 citation statements)

References 31 publications

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“…Simončič et al presented a new image processing algorithm for electrode tip displacement measurement. The purpose of their work introduced in [20] is to detect the electrode tips, determine the size of the reference areas on the electrode tips, and track these areas during the welding process. Authors suggested using a multi-shader graphics card and a camera with relatively low sampling frequency in order to decrease the execution time.…”

Section: Of 20mentioning

confidence: 99%

A Novel Method of Using Vision System and Fuzzy Logic for Quality Estimation of Resistance Spot Welding

Alghannam

et al. 2019

Symmetry

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Finding a reliable quality inspection system of resistance spot welding (RSW) has become a very important issue in the automobile industry. In this study, improvement in the quality estimation of the weld nugget’s surface on the car underbody is introduced using image processing methods and training a fuzzy inference system. Image segmentation, mathematical morphology (dilation and erosion), flood fill operation, least-squares fitting curve and some other new techniques such as location and value based selection of pixels are used to extract new geometrical characteristics from the weld nugget’s surface such as size and location, shape, and the numbers and areas of all side expulsions, peaks and troughs inside and outside the fusion zone. Topography of the weld nugget’s surface is created and shown as a 3D model based on the extracted geometrical characteristics from each spot. Extracted data is used to define input fuzzy functions for training a fuzzy logic inference system. Fuzzy logic rules are adopted based on knowledge database. The experiments are conducted on a 6 degree of freedom (DOF) robotic arm with a charge-coupled device (CCD) camera to collect pictures of various RSW locations on car underbodies. The results conclude that the estimation of the 3D model of the weld’s surface and weld’s quality can reach higher accuracy based on our proposed methods.

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Section: Of 20mentioning

confidence: 99%

A Novel Method of Using Vision System and Fuzzy Logic for Quality Estimation of Resistance Spot Welding

Alghannam

et al. 2019

Symmetry

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“…In the production environment, it is crucial to utilise dynamic signals to monitor weld quality and thus develop a feedback control system [10,11]. Electrode displacement (ED) has been extensively used to characterise the weld quality in a range of existing studies, via the techniques of image-process [12][13][14], non-contact laser displacement sensor [15,16] and contact-type displacement sensor [17,18]. ED curve describes the thermal expansion of sheets in the weld stage, where a range of factors affect the features of curves, such as surface conditions of the sheets [19], welding parameters [20] and electrode degradation [21].…”

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confidence: 99%

Characteristics of shunting effect in resistance spot welding in mild steel based on electrode displacement

2018

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Shunting effect of resistance spot welding is evaluated based on the electrode displacement signals. The shunted welds in mild steel with different weld spacing were produced. The results showed that the weld spacing and nugget diameter were polynomial-correlated, and the minimum welding spacing of 20 mm can be derived from the results. Both the peak value and gradient of electrode displacement in the weld stage indicated strong correlations with the nugget diameters of shunted welds. Additional shunt path was found to further aggregate the shunting, suggesting the decline in the values of profile features. Furthermore, it is found that the shunting effect led to the decline of the dynamic resistance curves, which is contradictive to the trends between acceptable-sized and undersized welds claimed based on the single weld study. The paper shows that electrode displacement curves of shunting can be incorporated into existing quality monitoring system.

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“…To ensure the weld quality, many scholars and experts employed a lot of process signals and relative mathematical tools to establish the models for online monitoring and controlling the weld quality. In general, dynamic resistance and electrode signal are two the most commonly used process variables, not only to online evaluate the weld quality [5,[10][11][12][13], but also to comprehensively analyze and understand the welding process [14][15][16][17]. Also, various sensors may be employed together to achieve the goal [18,19].…”

Section: Introductionmentioning

confidence: 99%

Online measuring the electrical resistivity of molten nugget of stainless steel in resistance spot welding

Zhou

Shi

Cai

2017

Journal of Manufacturing Processes

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The variation characteristics of electrical resistivity of the parent metal can improve in-depth understanding of the resistance spot welding (RSW) process. According to the characteristic of RSW process and the physical principle of electrical resistivity, a comprehensive mathematical description of the electrical resistivity measurement of the molten nugget can be obtained. Then a series of corresponding experiments, including the RSW operation to obtain the dynamic resistance, online temperature measurement to obtain the electrical resistivity of solid metals and metallurgical analyses to obtain the size of the molten nugget, were sequentially conducted. The results of the electrical resistivity of the molten nugget can be obtained according to relative measurements, calculations and analyses. The work can benefit the establishment of accurate mathematical model for RSW process, and then serve the welding automation, corresponding researches and actual production process.

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Image-based electrode tip displacement in resistance spot welding

Cited by 35 publications

References 31 publications

A Novel Method of Using Vision System and Fuzzy Logic for Quality Estimation of Resistance Spot Welding

A Novel Method of Using Vision System and Fuzzy Logic for Quality Estimation of Resistance Spot Welding

Characteristics of shunting effect in resistance spot welding in mild steel based on electrode displacement

Online measuring the electrical resistivity of molten nugget of stainless steel in resistance spot welding

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