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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Abstract
一种基于焊接过程热效应计算的电阻点焊焊点质量检测方法，该方法借助电阻点焊焊接过程中实时检测到的焊接电流信号、电极电压信号和焊接电流持续时间计算焊点形成过程产生的热效应，并基于计算得到的焊接热效应和对应焊点破坏性检测到的焊点直径、焊点最大承载力绘制关系曲线，从而建立热效应‑焊点直径数学模型和热效应‑焊点最大承载力数学模型。在计算机系统中建立不同厚度、不同材料的电阻点焊焊点质量数学模型数据库。在实际焊接过程中，在数据库中调用相应的数学模型，输入检测得到的热效应数值，计算机系统即计算并输出焊点直径值和最大承载力值，如小于相应的设定阈值，该焊点被判定为不合格。利用本发明可以快速实现对电阻点焊焊点直径、最大承载力的非破坏检测和评估，尤其适合焊接生产现场在线质量检测。
A method for detecting the quality of resistance spot welding solder joints based on the calculation of thermal effects in the welding process. The method uses the real-time detection of the welding current signal, electrode voltage signal and welding current duration during the resistance spot welding process to calculate the thermal effect of the solder joint formation process. , and draw a relational curve based on the calculated welding heat effect, the diameter of the solder joint destructively detected, and the maximum bearing capacity of the solder joint, so as to establish a mathematical model of thermal effect-solder joint diameter and a mathematical model of thermal effect-maximum bearing capacity of the solder joint. The mathematical model database of the resistance spot welding spot quality of different thicknesses and different materials is established in the computer system. In the actual welding process, call the corresponding mathematical model in the database, input the detected thermal effect value, the computer system will calculate and output the solder joint diameter value and the maximum bearing capacity value, if it is less than the corresponding set threshold value, the solder joint will be rejected It was judged as unqualified. The invention can quickly realize the non-destructive detection and evaluation of the diameter and the maximum bearing capacity of the resistance spot welding spot, and is especially suitable for on-line quality detection at the welding production site.
Description
技术领域technical field
本发明涉及一种利用焊接过程计算得到的焊接热效应评估电阻点焊焊点质量的方法，适用于常用金属薄板结构材料的焊点质量评估，尤其适用于生产现场在线质量检测。The invention relates to a method for evaluating the quality of resistance spot welding solder joints by using the welding heat effect calculated in the welding process, which is suitable for the evaluation of the solder joint quality of commonly used metal thin plate structural materials, and is especially suitable for on-line quality detection at the production site.
背景技术Background technique
电阻点焊是一种广泛应用于汽车制造的焊接方法，在现代轿车的车身金属结构焊接中得到了大量应用。因此，电阻点焊焊点质量的检测非常重要，焊接过程中高效率地对焊点质量进行传感和检测评估对于提高生产效率和焊接质量、节约生产成本具有重要意义。然而，电阻点焊过程中，焊点的形成隐藏于工件之中，并不能被直接观测到，这为对焊接质量进行实时传感以及在线评估焊点质量带来了困难。因此，在生产企业中，通常情况下均在焊后根据质量检验需要对生产的焊接结构产品抽取一定比例，并进行破坏性实验检测。检测主要针对焊点直径与焊点最大承载力这两个重要指标。其中，检测焊点直径需要撕开焊点焊接结构，测量其宏观尺寸；检测焊点最大承载力，需要进行拉剪强度测试。这样的检测方法不但效率低下，增加了生产成本，且不能保证未检测产品的质量可靠性。因此，电阻点焊过程中焊点质量信息的传感对于利用无损检测方法在线评估电阻点焊焊点质量具有重要的意义。为此，研究者采用多种方法检测焊点以表征其质量。Resistance spot welding is a welding method widely used in automobile manufacturing, and has been widely used in the welding of metal structures of modern passenger cars. Therefore, the detection of the quality of resistance spot welding solder joints is very important. Efficient sensing and detection and evaluation of solder joint quality during the welding process is of great significance for improving production efficiency and welding quality, and saving production costs. However, in the process of resistance spot welding, the formation of solder joints is hidden in the workpiece and cannot be directly observed, which brings difficulties for real-time sensing of welding quality and online evaluation of solder joint quality. Therefore, in production enterprises, usually after welding, a certain proportion of the welded structure products produced is selected according to the quality inspection requirements, and destructive experimental testing is carried out. The detection is mainly aimed at the two important indicators of the diameter of the solder joint and the maximum bearing capacity of the solder joint. Among them, to detect the diameter of the solder joint, it is necessary to tear the welding structure of the solder joint and measure its macroscopic size; to detect the maximum bearing capacity of the solder joint, a tensile and shear strength test is required. Such a detection method is not only inefficient, but also increases production costs, and cannot guarantee the quality and reliability of untested products. Therefore, the sensing of solder joint quality information in the process of resistance spot welding is of great significance for online evaluation of resistance spot welding joint quality by using non-destructive testing methods. To this end, researchers use a variety of methods to detect solder joints to characterize their quality.
中国专利文献CN1609622A公开的点焊熔核直径的实时检测方法采用如下步骤：取与焊接件相同厚度的焊接试样进行多点点焊，通过测量与计算获得每点的动态电阻曲线；进而获得每点的准稳态电阻值rD；沿贴合面剖开焊接试样，测量每个焊点的熔核直径d核；根据每个焊点熔核直径d核与准稳态电阻值rD的对应关系，绘制出准稳态电阻值rD与熔核直径d核关系曲线；将不同厚度材料的rD-d核曲线存储在计算机系统中，当点焊某种材料时，计算机系统先获得该焊点的准稳态电阻值rD，再与相同厚度材料的rD-d核曲线进行比较可获得对应的熔核直径，当熔核直径小于设定的标准值时，判定焊点质量不合格，实现实时检测。The real-time detection method of spot welding nugget diameter disclosed in Chinese patent document CN1609622A adopts the following steps: take a welding sample with the same thickness as the weldment and carry out multi-point spot welding, and obtain the dynamic resistance curve of each point through measurement and calculation; The quasi-steady-state resistance value r D ; cut the welding sample along the joint surface, and measure the nugget diameter d core of each solder joint; according to the relationship between the nugget diameter d core of each solder joint and the quasi-steady-state resistance value r D According to the corresponding relationship, the relationship curve between the quasi-steady-state resistance value r D and the nugget diameter d core is drawn; the r D -d core curves of materials with different thicknesses are stored in the computer system. When spot welding a certain material, the computer system first obtains The quasi-steady-state resistance value r D of the solder joint is compared with the r D -d nuclear curve of the same thickness material to obtain the corresponding nugget diameter. When the nugget diameter is smaller than the set standard value, the quality of the solder joint is judged Unqualified, realize real-time detection.
中国专利文献CN101241001A公开的铝合金电阻点焊熔核直径实时检测方法采用如下步骤：采集点焊过程中的电极位移信号，并绘制出电极位移信号曲线图；从所得的电极位移信号曲线上提取出膨胀位移和锻压位移两个特征值；将铝合金焊接试板撕开，对电阻点焊熔核直径进行实测，建立所提取的特征值与实测的熔核直径相对应的样本对，并形成训练集；建立人工神经网络模型，并用所得样本对对模型依据BP算法进行训练，实现从特征值到熔核直径的映射；人工神经网络模型是两个输入、一个输出，中间一个隐层，隐层结点的数目是5的结构，隐层的转移函数为Sigmoid函数，输出层的转移函数为线性函数；将训练好的模型用于铝合金电阻点焊熔核直径的在线实时检测。The disclosed aluminum alloy resistance spot welding nugget diameter real-time detection method of Chinese patent document CN101241001A adopts the following steps: collect the electrode displacement signal in the spot welding process, and draw the electrode displacement signal curve; Two eigenvalues of expansion displacement and forging displacement; the aluminum alloy welding test plate is torn apart, the diameter of the resistance spot welding nugget is measured, and a sample pair corresponding to the extracted eigenvalue and the measured nugget diameter is established, and a training set; establish an artificial neural network model, and use the obtained sample pairs to train the model according to the BP algorithm to realize the mapping from the feature value to the diameter of the nugget; the artificial neural network model has two inputs, one output, a hidden layer in the middle, and a hidden layer The number of nodes is a structure of 5, the transfer function of the hidden layer is a Sigmoid function, and the transfer function of the output layer is a linear function; the trained model is used for online real-time detection of aluminum alloy resistance spot welding nugget diameter.
中国专利文献CN1220034C公开的多信息融合技术确定铝合金板材电阻点焊熔核面积的方法采用如下步骤：依据小波包变换及其能量谱原理、依据信息熵原理、依据模态分析原理，计算出点焊过程中电极电压、电流、电极位移和声音信号的特征量，建立神经网络模型，由特征量和熔核面积对神经网络模型进行训练。神经网络模型计算出的熔核面积与实测熔核面积对照，确定误差值，调整神经网络模型，直至达到误差要求范围。The multi-information fusion technology disclosed in Chinese patent document CN1220034C adopts the following steps to determine the nugget area of resistance spot welding of aluminum alloy plates: according to the principle of wavelet packet transform and its energy spectrum, according to the principle of information entropy, and according to the principle of modal analysis, calculate the point The characteristic quantities of electrode voltage, current, electrode displacement and sound signal in the welding process are used to establish a neural network model, and the neural network model is trained by the characteristic quantities and nugget area. The nugget area calculated by the neural network model is compared with the measured nugget area, the error value is determined, and the neural network model is adjusted until the required error range is reached.
在电阻点焊过程中，焊点形成所需要的能量主要由焊接过程产生的电阻热效应来提供。而电阻热效应则主要由流过二次回路的焊接电流产生，随着焊点形成过程变化，焊点两端的电极电压也会发生相应的变化。因此，利用焊接电流和电极电压乘积的时间累积效应即可计算得到焊点形成过程所产生的电阻热效应。如式(1)所示：In the resistance spot welding process, the energy required for the formation of solder joints is mainly provided by the resistance heating effect generated during the welding process. The resistance heating effect is mainly generated by the welding current flowing through the secondary circuit. As the solder joint formation process changes, the electrode voltage at both ends of the solder joint will also change accordingly. Therefore, the resistance heating effect produced by the solder joint formation process can be calculated by using the time accumulation effect of the product of the welding current and the electrode voltage. As shown in formula (1):
其中，Q为电阻热效应，U(t)为电极电压的变化，I(t)为焊接电流的变化，焊接电流持续时间为t1-t0。可见，实现对电阻点焊过程热效应的实时检测和计算为电阻点焊焊点质量信息的在线传感和评估提供了可能。Among them, Q is the resistance heating effect, U(t) is the change of electrode voltage, I(t) is the change of welding current, and the duration of welding current is t 1 -t 0 . It can be seen that the real-time detection and calculation of the thermal effect of the resistance spot welding process provides the possibility for the online sensing and evaluation of the quality information of the resistance spot welding joints.
发明内容Contents of the invention
本发明针对常用金属薄板结构材料的电阻点焊，提供一种基于焊接过程热效应计算的焊点质量检测方法，该方法采用与焊点形成过程关系密切的焊接电流、电极电压为信息源，因此，检测结果可靠，检测成本消耗低，且尤其适合焊接生产现场的在线质量检测。Aiming at the resistance spot welding of commonly used metal thin plate structural materials, the present invention provides a method for detecting the quality of solder joints based on the calculation of thermal effects in the welding process. The method uses welding current and electrode voltage closely related to the formation process of solder joints as information sources. Therefore, The detection result is reliable, the detection cost is low, and it is especially suitable for online quality detection at the welding production site.
本发明采取以下技术方案：The present invention takes the following technical solutions:
一种基于焊接过程热效应计算的电阻点焊焊点质量检测方法，该方法借助电阻点焊焊接过程中实时检测到的焊接电流信号、电极电压信号和焊接电流时间计算焊点形成过程产生的热效应，并利用热效应检测、评估电阻点焊焊点尺寸和焊点最大承载力，所述检测方法的步骤如下：A method for detecting the quality of resistance spot welding solder joints based on the calculation of thermal effects in the welding process. The method uses the real-time detected welding current signal, electrode voltage signal and welding current time during the resistance spot welding process to calculate the thermal effect generated during the formation of solder joints. And utilize thermal effect to detect, evaluate resistance spot welding solder joint size and solder joint maximum bearing capacity, the step of described detection method is as follows:
(1)设定不少于十五组焊接电流、焊接电流持续时间、电极压力参数进行电阻点焊，对每一焊接过程实时采集电阻点焊机次级回路中的电阻点焊过程焊接电流信号和电极电压信号；(1) Set no less than fifteen sets of welding current, welding current duration, and electrode pressure parameters for resistance spot welding, and collect the welding current signal of the resistance spot welding process in the secondary circuit of the resistance spot welding machine in real time for each welding process and electrode voltage signal;
(2)在计算机系统中绘制出焊接电流和电极电压随时间变化的信号波形，检查波形波动幅值和周期的可靠性；(2) Draw the signal waveform of welding current and electrode voltage changing with time in the computer system, and check the reliability of the waveform fluctuation amplitude and cycle;
(3)利用计算机系统对焊接电流信号、电极电压信号波形作乘法运算，并基于焊接电流持续时间作定积分运算，得到焊接过程热效应数值；(3) Use the computer system to perform multiplication operations on the welding current signal and the electrode voltage signal waveform, and perform definite integral operations based on the duration of the welding current to obtain the value of the thermal effect of the welding process;
(4)通过截取焊点横截面检测获得上述各组焊接工艺参数焊接所得焊点的直径，通过拉剪实验获得焊点最大承载力；(4) Obtain the diameter of the solder joint obtained by welding the above-mentioned groups of welding process parameters by intercepting the cross-section of the solder joint, and obtain the maximum bearing capacity of the solder joint through the tensile shear test;
(5)以计算得到的焊接过程热效应数值为X轴，以检测得到的焊点直径或最大承载力为Y轴，利用计算机系统绘制出关系曲线，并拟合得到热效应-焊点直径数学模型或热效应-焊点最大承载力数学模型；(5) Take the calculated value of the thermal effect of the welding process as the X-axis, and use the detected solder joint diameter or maximum bearing capacity as the Y-axis, use a computer system to draw a relationship curve, and fit the mathematical model of thermal effect-solder joint diameter or Thermal effect - the mathematical model of the maximum bearing capacity of solder joints;
(6)在计算机系统中根据上述步骤建立不同厚度、不同材料的电阻点焊焊点质量数学模型数据库；(6) In the computer system, according to the above-mentioned steps, the mathematical model database of the resistance spot welding solder joint quality of different thicknesses and different materials is established;
(7)根据采用的质量检验标准，设定不同厚度、不同材料的电阻点焊焊点直径参考阈值和最大承载力参考阈值；(7) According to the adopted quality inspection standard, set the reference threshold value of the resistance spot welding spot diameter and the maximum bearing capacity reference threshold value of different thicknesses and different materials;
(8)在实际焊接过程中，在数据库中调用相应的数学模型，输入检测得到的热效应数值，计算机系统即计算并输出焊点直径值和最大承载力值，如小于相应的设定阈值，该焊点被判定为不合格。(8) In the actual welding process, call the corresponding mathematical model in the database, input the thermal effect value obtained by the detection, the computer system will calculate and output the solder joint diameter value and the maximum bearing capacity value, if it is less than the corresponding set threshold value, the Solder joints were judged to be unacceptable.
本发明的创新在于以实时监测到的电阻点焊过程焊接电流和电极电压作为信息源计算获得焊点形成过程产生的热效应，通过建立焊接热效应和焊点直径、焊点最大承载力之间的关系模型，实现对电阻点焊焊点直径和最大承载力的快速、无损检测和评估。The innovation of the present invention is to use the real-time monitored welding current and electrode voltage of the resistance spot welding process as an information source to calculate the thermal effect generated during the formation of the solder joint, and establish the relationship between the welding thermal effect, the diameter of the solder joint, and the maximum bearing capacity of the solder joint Model for rapid, non-destructive testing and evaluation of resistance spot weld joint diameter and maximum load-carrying capacity.
本发明适用于焊接生产现场在线快速检测和评定电阻点焊焊点质量信息。与现有技术相比，本发明具有以下优点：The invention is suitable for on-line rapid detection and evaluation of the quality information of resistance spot welding solder joints on the welding production site. Compared with the prior art, the present invention has the following advantages:
(1)所采用的信息源——焊接电流和电极电压与焊点形成过程关系密切，计算得到的焊接热效应与焊点质量相关性强，使检测结果可靠性高；(1) The information sources used - welding current and electrode voltage are closely related to the formation process of solder joints, and the calculated welding thermal effect has a strong correlation with the quality of solder joints, making the detection results highly reliable;
(2)信号检测系统容易实现，系统设计制造成本较为低廉；(2) The signal detection system is easy to implement, and the system design and manufacturing cost is relatively low;
(3)能够比较快捷地检测焊点质量信息，形成对电阻点焊工艺和质量的评估，适用的材料范围较广，实用性较强；(3) It can quickly detect the quality information of solder joints, form an evaluation of the resistance spot welding process and quality, and has a wide range of applicable materials and strong practicability;
(4)检测效率高，评定方法简单，适用于电阻点焊生产现场的在线质量检测和质量评定。(4) The detection efficiency is high, the evaluation method is simple, and it is suitable for online quality inspection and quality evaluation at the production site of resistance spot welding.
附图说明Description of drawings
图1是实施例1检测到的低碳钢板材电阻点焊过程的焊接电流信号波形。Fig. 1 is the welding current signal waveform of the resistance spot welding process of the low carbon steel plate detected in the first embodiment.
图2是实施例1检测到的低碳钢板材电阻点焊过程的电极电压信号波形。Fig. 2 is the electrode voltage signal waveform of the low carbon steel plate resistance spot welding process detected in Example 1.
图3是实施例1破坏性检测得到的熔核宏观形貌。Fig. 3 is the macroscopic morphology of the nugget obtained by the destructive detection in Example 1.
图4是实施例1破坏性检测得到的焊点拉剪力学性能曲线。。Fig. 4 is the tensile-shear mechanical property curve of the solder joint obtained from the destructive test in Example 1. .
图5是建立的焊接热效应与焊点直径关系曲线Figure 5 is the established relationship curve between welding heat effect and solder joint diameter
图6是建立的焊接热效应与焊点最大承载力关系曲线。Figure 6 is the relationship curve between the established welding heat effect and the maximum bearing capacity of the solder joint.
图7是实施例2检测到的低碳钢板材电阻点焊过程的焊接电流信号波形。Fig. 7 is the welding current signal waveform of the low carbon steel plate resistance spot welding process detected in the second embodiment.
图8是实施例2检测到的低碳钢板材电阻点焊过程的电极电压信号波形。Fig. 8 is the electrode voltage signal waveform of the low carbon steel plate resistance spot welding process detected in Example 2.
图9是实施例2破坏性检测得到的熔核宏观形貌。Fig. 9 is the macroscopic morphology of the nugget obtained from the destructive detection in Example 2.
图10是实施例2破坏性检测得到的焊点拉剪力学性能曲线。Fig. 10 is the tensile-shear mechanical property curve of the solder joint obtained from the destructive test in Example 2.
具体实施方式detailed description
下面结合具体实施例，进一步阐述本发明。Below in conjunction with specific embodiment, further illustrate the present invention.
实施例1：Example 1:
待焊接的工件为两块厚度1mm的低碳钢材料薄板结构的搭接。采用的主要焊接工艺参数为：焊接电流为6000A，焊接电流持续时间为0.28s，电极压力为0.15MPa。The workpiece to be welded is the overlapping joint of two low-carbon steel sheet structures with a thickness of 1 mm. The main welding process parameters used are: welding current is 6000A, welding current duration is 0.28s, electrode pressure is 0.15MPa.
焊接中，实时采集电阻点焊过程的焊接电流信号和电极电压信号，由分析软件绘出信号波形图，分别如图1和图2所示。During welding, the welding current signal and electrode voltage signal of the resistance spot welding process are collected in real time, and the signal waveform is drawn by the analysis software, as shown in Figure 1 and Figure 2 respectively.
通过定积分计算该焊接工艺产生的焊接热效应为23.231kJ。The welding heat effect produced by this welding process is calculated by definite integral to be 23.231kJ.
采用十五组不同的焊接工艺参数进行焊接和测试，其中，焊接电流为4500A～8000A，电极压力为0.1MPa～0.2MPa，焊接电流持续时间为0.16s～0.38s。根据实时检测得到的焊接电流和电极电压，计算得到十五组焊接工艺形成焊点的焊接热效应。对各组得到的焊点分别进行焊点直径和最大承载力破坏性检测。建立焊接热效应与焊点直径、焊点最大承载力关系曲线如图5和图6所示。其中，根据图5中的关系，拟合得到热效应-焊点直径数学模型为：D＝6.241-3.371×10-4Q+1.076×10-8Q2；根据图6中的关系，拟合得到的热效应-焊点最大承载力数学模型为：F＝5.319-2982.749exp(-Q/2367.085)。Fifteen sets of different welding process parameters are used for welding and testing, among which, the welding current is 4500A-8000A, the electrode pressure is 0.1MPa-0.2MPa, and the welding current duration is 0.16s-0.38s. According to the welding current and electrode voltage obtained by real-time detection, the welding heat effect of welding joints formed by fifteen sets of welding processes is calculated. The solder joints obtained in each group were subjected to destructive testing on the diameter of the solder joints and the maximum bearing capacity. Establish the relationship curve between welding heat effect, solder joint diameter and maximum bearing capacity of solder joint, as shown in Figure 5 and Figure 6. Among them, according to the relationship in Figure 5, the mathematical model of thermal effect-solder spot diameter is obtained by fitting: D=6.241-3.371×10 -4 Q+1.076×10 -8 Q 2 ; according to the relationship in Figure 6, the fitting is The thermal effect-mathematical model of the maximum bearing capacity of solder joints is: F=5.319-2982.749exp(-Q/2367.085).
根据建立的数学模型对实施例1中的焊点直径进行计算得4.217mm，实测直径为4.014mm，焊点成核如图3所示，误差为5.06％；对焊点最大承载力进行计算得5.15kN，实测拉剪载荷为4.92kN，焊点破坏性检测得到的拉剪力学性能曲线如图4所示，误差为4.67％。According to the established mathematical model, the diameter of the solder joint in Example 1 is calculated to be 4.217mm, and the measured diameter is 4.014mm. The nucleation of the solder joint is shown in Figure 3, and the error is 5.06%; the maximum bearing capacity of the solder joint is calculated. 5.15kN, the measured tensile-shear load is 4.92kN, the tensile-shear mechanical property curve obtained from the destructive testing of solder joints is shown in Figure 4, and the error is 4.67%.
该结果表明，利用本发明所述方法可以较为准确快捷地实现对电阻点焊焊点直径和最大承载力的非破坏性检测和评估。The result shows that the non-destructive detection and evaluation of the diameter and maximum bearing capacity of the resistance spot welding spot can be realized more accurately and quickly by using the method of the present invention.
实施例2：Example 2:
待焊接的工件为两块厚度1mm的低碳钢材料薄板结构的搭接。采用的主要焊接工艺参数为：焊接电流为4500A，焊接电流持续时间为0.24s，电极压力为0.15MPa。The workpiece to be welded is the overlapping joint of two low-carbon steel sheet structures with a thickness of 1mm. The main welding process parameters used are: welding current is 4500A, welding current duration is 0.24s, electrode pressure is 0.15MPa.
焊接中，实时采集电阻点焊过程的焊接电流信号和电极电压信号，由分析软件绘出信号波形图，分别如图7和图8所示。During welding, the welding current signal and electrode voltage signal of the resistance spot welding process are collected in real time, and the signal waveform diagram is drawn by the analysis software, as shown in Figure 7 and Figure 8 respectively.
通过定积分计算该焊接工艺产生的焊接热效应为16.281kJ。The welding heat effect produced by this welding process is calculated by definite integral to be 16.281kJ.
采用十五组不同的焊接工艺参数进行焊接和测试，其中，焊接电流为4500A～8000A，电极压力为0.1MPa～0.2MPa，焊接电流持续时间为0.16s～0.38s。根据实时检测得到的焊接电流和电极电压，计算得到十五组焊接工艺形成焊点的焊接热效应。对各组得到的焊点分别进行焊点直径和最大承载力破坏性检测。建立焊接热效应与焊点直径、焊点最大承载力关系曲线如图5和图6所示。其中，根据图5中的关系，拟合得到热效应-焊点直径数学模型为：D＝6.241-3.371×10-4Q+1.076×10-8Q2；根据图6中的关系，拟合得到的热效应-焊点最大承载力数学模型为：F＝5.319-2982.749exp(-Q/2367.085)。Fifteen sets of different welding process parameters are used for welding and testing, among which, the welding current is 4500A-8000A, the electrode pressure is 0.1MPa-0.2MPa, and the welding current duration is 0.16s-0.38s. According to the welding current and electrode voltage obtained by real-time detection, the welding heat effect of welding joints formed by fifteen sets of welding processes is calculated. The solder joints obtained in each group were subjected to destructive testing on the diameter of the solder joints and the maximum bearing capacity. Establish the relationship curve between welding heat effect, solder joint diameter and maximum bearing capacity of solder joint, as shown in Figure 5 and Figure 6. Among them, according to the relationship in Figure 5, the mathematical model of thermal effect-solder spot diameter is obtained by fitting: D=6.241-3.371×10 -4 Q+1.076×10 -8 Q 2 ; according to the relationship in Figure 6, the fitting is The thermal effect-mathematical model of the maximum bearing capacity of solder joints is: F=5.319-2982.749exp(-Q/2367.085).
根据建立的数学模型对实施例2中的焊点直径进行计算得3.605mm，实测直径为3.779mm，误差为4.60％；对焊点最大承载力进行计算得2.246kN，实测拉剪载荷为2.382kN，误差为5.71％。According to the established mathematical model, the diameter of the solder joint in Example 2 is calculated to be 3.605mm, the measured diameter is 3.779mm, and the error is 4.60%; the maximum bearing capacity of the solder joint is calculated to be 2.246kN, and the measured tensile and shear load is 2.382kN , with an error of 5.71%.
该结果表明，利用本发明所述方法可以较为准确快捷地实现对电阻点焊焊点直径和最大承载力的非破坏性检测和评估。The result shows that the non-destructive detection and evaluation of the diameter and maximum bearing capacity of the resistance spot welding spot can be realized more accurately and quickly by using the method of the present invention.
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