CN104677751B - Quality detection method for resistance-spot-welding spots on basis of calculation of thermal effect of welding process - Google Patents
Quality detection method for resistance-spot-welding spots on basis of calculation of thermal effect of welding process Download PDFInfo
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- CN104677751B CN104677751B CN201510091370.5A CN201510091370A CN104677751B CN 104677751 B CN104677751 B CN 104677751B CN 201510091370 A CN201510091370 A CN 201510091370A CN 104677751 B CN104677751 B CN 104677751B
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Abstract
The invention discloses a quality detection method for resistance-spot-welding spots on the basis of calculation of the thermal effect of a welding process. The method comprises the following steps: calculating the thermal effect generated in the welding-spot forming process by means of welding current signals, electrode voltage signals and welding-current duration time detected in the process of resistance spot welding in real time, and drawing a relation curve on the basis of the welding thermal effect obtained by calculation and the welding-spot diameter and the maximum welding-spot bearing capacity detected corresponding to the welding-spot destructiveness so as to establish a mathematical model of the thermal effect and the welding-spot diameter and a mathematical model of the thermal effect and the maximum welding-spot bearing capacity; establishing a database of mathematical models for the quality of the resistance-spot-welding spots with different thicknesses and different materials in a computer system; and in the practical welding process, calling corresponding mathematical models in the database, inputting the thermal-effect value obtained by detection, then calculating and outputting the diameter values and maximum bearing capacity values of the welding spots by the computer system, and if the values are less than corresponding set threshold values, judging that the welding spots are unqualified. The quality detection method has the advantages that the nondestructive detection and evaluation of the diameters and the maximum bearing capacities of the resistance-spot-welding spots can be quickly realized, so that the quality detection method is especially suitable for online quality detection on a welding production site.
Description
Technical field
The present invention relates to a kind of calculated welding effect assessment resistance spot welding quality of welding spot of utilization welding process
Method, it is adaptable to the quality of welding spot assessment of common metal thin-plate structure muterial, is particularly suited for production scene online quality control.
Background technology
Resistance spot welding is a kind of welding method for being widely used in automobile making, is welded in the vehicle body metal structure of Modern Car
Widely applied in connecing.Therefore, the detection of resistance spot welding quality of welding spot is extremely important, expeditiously butt welding in welding process
It is significant for improve production efficiency and welding quality, saving production cost that point mass carries out sensing and check and evaluation.
However, in resistance spot welding process, among the formation of solder joint is hidden in workpiece, can not be directly observed, this is to welding matter
Amount carries out real-time sensing and online evaluation quality of welding spot brings difficulty.Therefore, in manufacturing enterprise, exist under normal circumstances
Postwelding needs the welding structure product to producing to extract certain proportion according to quality inspection, and carries out destructive test detection.Inspection
Survey mainly for spot size and the two important indicators of solder joint maximum load capacity.Wherein, detect that spot size needs to tear weldering
Spot welding structure, measures its macro-size；Detection solder joint maximum load capacity, needs to carry out tensile-sbear strength test.Such detection
Method not only inefficiency, increased production cost, and it cannot be guaranteed that does not detect the reliability of product.Therefore, point of resistance
During weldering, the sensing of quality of welding spot information is heavy for having using lossless detection method online evaluation resistance spot welding quality of welding spot
The meaning wanted.For this purpose, researcher adopts various methods to detect solder joint to characterize its quality.
The real-time detection method of dot weld nugget diameter disclosed in Chinese patent literature CN1609622A adopts following steps：Take
Multiple spot welding is carried out with the welded specimen of weldment same thickness, by measurement and the dynamic resistance curve for calculating acquisition per；
And then obtain quasi-steady state resistance value r of perD；Welded specimen is cut open along binding face, the nugget size d of each solder joint is measuredCore；Root
According to each nugget diameter dCoreWith quasi-steady state resistance value rDCorresponding relation, draw out quasi-steady state resistance value rDWith nugget size
dCoreRelation curve；By the r of different-thickness materialD-dCoreCurve is stored in computer systems, when certain material of spot welding, is calculated
Machine system first obtains quasi-steady state resistance value r of the solder jointD, then the r with same thickness materialD-dCoreCurve is compared and can obtain right
The nugget size answered, when standard value of the nugget size less than setting, judges that quality of welding spot is unqualified, realizes real-time detection.
Aluminium alloy resistance spot welding nugget size real-time detection method disclosed in Chinese patent literature CN101241001A is adopted
Following steps：Electrode displacement signals during resistance during collection spot welding, and draw out electrode displacement signals during resistance curve chart；From the electrode of gained
Expansion displacement and forging and stamping two eigenvalues of displacement are extracted on displacement signal curve；Welded test plate (panel) is torn, to resistance
Dot weld nugget diameter is surveyed, and is set up the extracted eigenvalue sample pair corresponding with the nugget size of actual measurement, and is formed
Training set；Artificial nerve network model is set up, and is realized from feature to being trained according to BP algorithm to model with gained sample
It is worth the mapping of nugget size；Artificial nerve network model is two inputs, an output, a middle hidden layer, hidden layer node
Number be 5 structure, the transfer function of hidden layer is Sigmoid functions, and the transfer function of output layer is linear function；Will training
Good model is used for the on-line real-time measuremen of aluminium alloy resistance spot welding nugget size.
Multi-information merging technology disclosed in Chinese patent literature CN1220034C determines aluminum alloy plate materials nugget formation in resistance spot welding
The method of area adopts following steps：According to wavelet package transforms and its energy spectrum principle, according to information entropy principle, according to mode point
Analysis principle, calculates the characteristic quantity of electrode voltage, electric current, electrode displacement and acoustical signal in pinpoint welding procedure, sets up neutral net
Model, is trained to neural network model by characteristic quantity and nugget area.Nugget area that neural network model is calculated with
The area control of actual measurement nugget, determines error amount, adjusts neural network model, until it reaches error requirements scope.
In resistance spot welding process, the energy required for solder joint is formed mainly is come by the resistance heat effect that welding process is produced
There is provided.And resistance heat effect is then mainly produced by the welding current for flowing through secondary circuit, as solder joint forming process changes, solder joint
The electrode voltage at two ends can also occur corresponding change.Therefore, imitated using the accumulated time of welding current and electrode voltage product
The resistance heat effect that should be calculated produced by solder joint forming process.As shown in formula (1)：
Wherein, Q be resistance heat effect, changes of the U (t) for electrode voltage, changes of the I (t) for welding current, welding current
Persistent period is t1-t0.It can be seen that, realize the real-time detection to resistance spot welding process heat effect and be calculated as resistance spot welding solder joint matter
The online sensing of amount information and assessment are there is provided possible.
The content of the invention
Resistance spot welding of the present invention for common metal thin-plate structure muterial, there is provided a kind of accrued based on welding process thermal effect
The quality of welding spot detection method of calculation, the method adopt the welding current in close relations with solder joint forming process, electrode voltage for letter
Breath source, therefore, testing result reliability, testing cost consume low, and are especially suitable for the online quality control at welding production scene.
The present invention takes technical scheme below：
A kind of resistance spot welding quality of welding spot detection method calculated based on welding process heat effect, the method is by point of resistance
In weldering welding process real-time detection to welding current signal, electrode voltage signal and welding current Time Calculation solder joint formed
The heat effect that journey is produced, and using heat effect detection, assessment resistance spot welding welding spot size and solder joint maximum load capacity, the detection
The step of method, is as follows：
(1) setting carries out point of resistance no less than 15 bond pads electric currents, welding current persistent period, electrode pressure parameter
Weldering, to resistance spot welding process welding current signal and electrode in each welding process Real-time Collection resistance spot weld secondary loop
Voltage signal；
(2) welding current and the time dependent signal waveform of electrode voltage are drawn out in computer systems, check ripple
Shape fluctuation amplitude and the reliability in cycle；
(3) make multiplying to welding current signal, electrode voltage signal waveform using computer system, and based on welding
Current duration makees definite integral computing, obtains welding process heat effect numerical value；
(4) diameter for obtaining solder joint obtained by above-mentioned each group welding condition welding is detected as intercepting solder joint cross section,
Experiment acquisition solder joint maximum load capacity is cut by drawing；
(5) with calculated welding process heat effect numerical value as X-axis, to detect the spot size or maximum carrying that obtain
Power is Y-axis, draws out relation curve using computer system, and fitting obtains heat effect-spot size mathematical model or thermal effect
Should-solder joint maximum load capacity mathematical model；
(6) set up the resistance spot welding quality of welding spot of different-thickness, different materials in computer systems according to above-mentioned steps
Mathematical model data base；
(7) according to the quality control standards (QCS) for adopting, set the resistance spot welding spot size reference of different-thickness, different materials
Threshold value and maximum load capacity reference threshold；
(8) during actual welding, corresponding mathematical model, the heat effect that input detection is obtained are called in data base
Numerical value, computer system calculate and export spot size value and maximum load capacity value, such as less than corresponding given threshold, the weldering
Point is judged as unqualified.
The innovation of the present invention is resistance spot welding process welding current and electrode voltage to real-time monitor as information
Source calculates the heat effect for obtaining that solder joint forming process is produced, by setting up welding effect and the maximum carrying of spot size, solder joint
Relational model between power, realizes to resistance spot welding spot size and the quick of maximum load capacity, Non-Destructive Testing and assessment.
The present invention is applied to welding production scene on-line quick detection and evaluation resistance spot welding quality of welding spot information.With it is existing
Technology is compared, and the present invention has advantages below：
(1) information source for being adopted --- welding current and electrode voltage are in close relations with solder joint forming process, calculate
The welding effect for arriving is strong with quality of welding spot dependency, makes testing result reliability high；
(2) signal detection system easily realizes that system design manufacturing cost is more cheap；
(3) quality of welding spot information can be detected fastly, the assessment to resistance spot welding process and quality is formed, and be suitable for
Material ranges it is wider, practicality is stronger；
(4) detection efficiency is high, and assessment method is simple, it is adaptable to the online quality control and quality of resistance spot welding production scene
Evaluation.
Description of the drawings
Fig. 1 is the welding current signal waveform of the low-carbon steel plate resistance spot welding process that embodiment 1 is detected.
Fig. 2 is the electrode voltage signal waveform of the low-carbon steel plate resistance spot welding process that embodiment 1 is detected.
Fig. 3 is the nugget macro morphology that 1 destructive detection of embodiment is obtained.
Fig. 4 is that mechanical curves are cut in the solder joint drawing that 1 destructive detection of embodiment is obtained..
Fig. 5 is the welding effect and spot size relation curve set up
Fig. 6 is the welding effect and solder joint maximum load capacity relation curve set up.
Fig. 7 is the welding current signal waveform of the low-carbon steel plate resistance spot welding process that embodiment 2 is detected.
Fig. 8 is the electrode voltage signal waveform of the low-carbon steel plate resistance spot welding process that embodiment 2 is detected.
Fig. 9 is the nugget macro morphology that 2 destructive detection of embodiment is obtained.
Figure 10 is that mechanical curves are cut in the solder joint drawing that 2 destructive detection of embodiment is obtained.
Specific embodiment
With reference to specific embodiment, the present invention is expanded on further.
Embodiment 1：
Workpiece to be welded is the overlap joint of the low-carbon steel material thin-slab structure of two pieces of thickness 1mm.Using main Welder
Skill parameter is：Welding current is 6000A, and the welding current persistent period is 0.28s, and electrode pressure is 0.15MPa.
In welding, the welding current signal and electrode voltage signal of Real-time Collection resistance spot welding process are painted by analysis software
Go out signal waveforms, respectively as depicted in figs. 1 and 2.
The welding effect produced by the Definite Integral Calculation welding procedure is 23.231kJ.
Welded and tested using 15 groups of different welding conditions, wherein, welding current be 4500A～
8000A, electrode pressure are 0.1MPa～0.2MPa, and the welding current persistent period is 0.16s～0.38s.Obtained according to real-time detection
The welding current for arriving and electrode voltage, are calculated the welding effect that 15 bond pads techniques form solder joint.Each group is obtained
Solder joint carry out the destructive detection of spot size and maximum load capacity respectively.Set up welding effect with spot size, solder joint most
Large bearing capacity relation curve is as shown in Figure 5 and Figure 6.Wherein, according to the relation in Fig. 5, fitting obtains heat effect-spot size number
Learning model is：D=6.241-3.371 × 10-4Q+1.076×10-8Q2；According to the relation in Fig. 6, be fitted the heat effect that obtains-
Solder joint maximum load capacity mathematical model is：F=5.319-2982.749exp (- Q/2367.085).
Mathematical model according to setting up carries out calculating 4.217mm to the spot size in embodiment 1, and measured diameter is
4.014mm, solder joint nucleation is as shown in figure 3, error is 5.06%；Butt welding point maximum load capacity carries out calculating 5.15kN, actual measurement
Drawing shearing load is 4.92kN, and solder joint is destructive to detect that the drawing for obtaining cuts mechanical curves as shown in figure 4, error is 4.67%.
The result is shown, more accurately and quickly can be realized to resistance spot welding spot size using the method for the invention
With non-damaged data and the assessment of maximum load capacity.
Embodiment 2：
Workpiece to be welded is the overlap joint of the low-carbon steel material thin-slab structure of two pieces of thickness 1mm.Using main Welder
Skill parameter is：Welding current is 4500A, and the welding current persistent period is 0.24s, and electrode pressure is 0.15MPa.
In welding, the welding current signal and electrode voltage signal of Real-time Collection resistance spot welding process are painted by analysis software
Go out signal waveforms, respectively as shown in Figure 7 and Figure 8.
The welding effect produced by the Definite Integral Calculation welding procedure is 16.281kJ.
Welded and tested using 15 groups of different welding conditions, wherein, welding current be 4500A～
8000A, electrode pressure are 0.1MPa～0.2MPa, and the welding current persistent period is 0.16s～0.38s.Obtained according to real-time detection
The welding current for arriving and electrode voltage, are calculated the welding effect that 15 bond pads techniques form solder joint.Each group is obtained
Solder joint carry out the destructive detection of spot size and maximum load capacity respectively.Set up welding effect with spot size, solder joint most
Large bearing capacity relation curve is as shown in Figure 5 and Figure 6.Wherein, according to the relation in Fig. 5, fitting obtains heat effect-spot size number
Learning model is：D=6.241-3.371 × 10-4Q+1.076×10-8Q2；According to the relation in Fig. 6, be fitted the heat effect that obtains-
Solder joint maximum load capacity mathematical model is：F=5.319-2982.749exp (- Q/2367.085).
Mathematical model according to setting up carries out calculating 3.605mm to the spot size in embodiment 2, and measured diameter is
3.779mm, error are 4.60%；Butt welding point maximum load capacity carries out calculating 2.246kN, and it is 2.382kN that shearing load is drawn in actual measurement,
Error is 5.71%.
The result is shown, more accurately and quickly can be realized to resistance spot welding spot size using the method for the invention
With non-damaged data and the assessment of maximum load capacity.
Claims (1)
1. it is a kind of based on welding process heat effect calculate resistance spot welding quality of welding spot detection method, the method is by resistance spot welding
Welding current signal, electrode voltage signal and welding current Time Calculation solder joint forming process that in welding process, real-time detection is arrived
The heat effect of generation, and using heat effect detection, assessment resistance spot welding welding spot size and solder joint maximum load capacity, the detection side
The step of method, is as follows：
（1）For different materials different-thickness, setting is no less than 15 bond pads electric currents, welding current persistent period, electricity respectively
Extreme pressure force parameter carries out resistance spot welding, to the resistance spot welding in each welding process Real-time Collection resistance spot weld secondary loop
Journey welding current signal and electrode voltage signal；
（2）Welding current and the time dependent signal waveform of electrode voltage are drawn out in computer systems, check waveform ripple
Dynamic amplitude and the reliability in cycle；
（3）Make multiplying to welding current signal, electrode voltage signal waveform using computer system, and be based on welding current
Persistent period makees definite integral computing, obtains the resistance spot welding process heat effect numerical value that 15 bond pads technological parameters form solder joint；
（4）The diameter of solder joint as obtained by intercepting the detection acquisition 15 bond pads technological parameters welding of solder joint cross section, by drawing
Cut the maximum load capacity that experiment obtains 15 bond pads technological parameters welding gained solder joint；
（5）The resistance spot welding process heat effect numerical value of solder joint is formed as X-axis with calculated 15 bond pads technological parameter, with
The spot size or solder joint maximum load capacity of the 15 bond pads technological parameters welding gained that detection is obtained is Y-axis, using calculating
Machine system draws out relation curve, and fitting obtains heat effect-spot size mathematical model or heat effect-solder joint maximum load capacity
Mathematical model；
（6）Set up the resistance spot welding quality of welding spot mathematics of different-thickness, different materials in computer systems according to above-mentioned steps
Model database；
（7）According to the quality control standards (QCS) for adopting, setting different-thickness, the resistance spot welding spot size reference threshold of different materials
With maximum load capacity reference threshold；
（8）During actual welding, corresponding mathematical model, the heat effect number that input detection is obtained are called in data base
Value, computer system calculate and export spot size value and maximum load capacity value, such as less than corresponding given threshold, the solder joint
It is judged as unqualified.
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| CN107745176B (en) * | 2017-10-31 | 2020-04-17 | 天津七所高科技有限公司 | Parameter setting-free resistance spot welding control method and system |
| CN108535660A (en) * | 2018-04-26 | 2018-09-14 | 深圳市泰欣能源科技有限公司 | The detection device and its detection method of a kind of group of battery modules junction conduction |
| CN109409520B (en) * | 2018-10-17 | 2021-10-29 | 深圳市微埃智能科技有限公司 | Welding process parameter recommendation method and device based on transfer learning and robot |
| CN112529884B (en) * | 2020-12-17 | 2022-03-25 | 中国石油大学(华东) | Welding spot quality evaluation method based on indentation characteristic image recognition |
| CN115178845A (en) * | 2021-04-06 | 2022-10-14 | 上海汽车集团股份有限公司 | Calculation method of welding parameters of resistance spot welding and welding parameter control system |
| CN113977056B (en) * | 2021-10-27 | 2022-12-27 | 重庆理工大学 | Secondary current pulse-based resistance spot welding spot quality detection method |
| CN114918537A (en) * | 2022-05-20 | 2022-08-19 | 泰德激光惠州有限公司 | Welding method of vapor chamber and middle frame, laser processing equipment and heat dissipation structure |
| CN115128130B (en) * | 2022-06-22 | 2024-05-31 | 广东工业大学 | Online resistance spot welding quality assessment system and method based on dynamic resistance signals |
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