CN104730109B - A kind of resistance spot welding quality of welding spot detection method based on dynamic resistance curve - Google Patents
A kind of resistance spot welding quality of welding spot detection method based on dynamic resistance curve Download PDFInfo
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Abstract
A kind of resistance spot welding quality of welding spot detection method based on dynamic resistance curve, welding current signal, electrode voltage signal and welding current persistent period that the method arrives by real-time detection in resistance spot welding welding process calculate the dynamic electric resistor change curve of solder joint forming process and average dynamic electric resistor, and based on calculated average dynamic resistance and correspond to spot size, the solder joint maximum load capacity drafting relation curve that solder joint destructiveness detects, thus setting up average dynamic resistance spot weld diameter mathematical model and average dynamic electric resistor solder joint maximum load capacity mathematical model.During actual welding, the dynamic resistance curve that detection is obtained is compared with standard dynamic resistance curve, to judge solder joint nucleating events.Call corresponding mathematical model, the average dynamic resistance that input detection obtains in data base, computer system calculates and export spot size value and maximum load capacity value, such as less than corresponding given threshold, this solder joint is judged as unqualified.Can quickly be realized to resistance spot welding spot size, the non break down test of maximum load capacity and assessment, especially suitable welding production scene online quality control using the present invention.
Description
Technical field
The present invention relates to resistance spot welding quality of welding spot detection technique is it is adaptable to the solder joint matter of common metal thin-plate structure muterial
Amount assessment, is particularly suited for production scene online quality control.
Background technology
Resistance spot welding is a kind of welding method being widely used in automobile making, in the vehicle body metal structure weldering 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, the formation of solder joint is hidden among 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, all exist under normal circumstances
Postwelding, according to quality inspection, needs to extract certain proportion to the welding structure product producing, and carries out destructive test detection.Inspection
Survey mainly for spot size and this two important indicators of solder joint maximum load capacity.Wherein, detection 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 has weight for using lossless detection method online evaluation resistance spot welding quality of welding spot
The meaning wanted.For this reason, researcher adopts multiple method detection solder joints to characterize its quality.
The real-time detection method of dot weld nugget diameter disclosed in Chinese patent literature CN1609622A adopts following steps:Take
Carry out multiple spot welding with the welded specimen of weldment same thickness, by measurement and the dynamic resistance curve calculating acquisition every;
And then obtain quasi-steady state resistance value r of everyD;Cut welded specimen open along binding face, measure the nugget size d of each solder jointCore;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;R by different-thickness materialD-dCoreCurve stores in computer systems, when certain material of spot welding, calculates
Machine system first obtains quasi-steady state resistance value r of this solder jointD, then the r with same thickness materialD-dCoreCurve be compared can obtain right
The nugget size answered, when nugget size is less than the standard value 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 adopts
Following steps:Electrode displacement signals during resistance during collection spot welding, and draw out electrode displacement signals during resistance curve chart;Electrode from 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 sets up the extracted eigenvalue sample pair corresponding with the nugget size of actual measurement, and is formed
Training set;Set up artificial nerve network model, and be trained according to BP algorithm to model with gained sample, realize from feature
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 function, and the transfer function of output layer is linear function;To train
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:Divide according to wavelet package transforms and its energy spectrum principle, according to information entropy principle, according to mode
Analysis principle, calculates the characteristic quantity of electrode voltage in pinpoint welding procedure, electric current, electrode displacement and acoustical signal, sets up neutral net
Model, is trained to neural network model by characteristic quantity and nugget area.The nugget area that neural network model calculates with
Actual measurement nugget area comparison, determines error amount, adjusts neural network model, until it reaches error requirements scope.
In resistance spot welding process, the energy that welding current is provided is relied on to make material interface forming core to be welded, with molten
The nucleation of core and growing up, the dynamic electric resistor of solder joint produces real-time change, and this change is also subject to welding thermal effect to a great extent
The impact answered.And welding effect is mainly produced by the welding current flowing through secondary circuit, with the change of solder joint forming process, weldering
The electrode voltage at point two ends also can occur to change accordingly.Therefore, using the accumulated time effect of welding current and electrode voltage
The dynamic electric resistor change of solder joint forming process can be calculated.As shown in formula (1):
Wherein, R (t) is time dependent dynamic electric resistor, and U (t) is the change of electrode voltage, and I (t) is welding current
Change.It can be seen that, dynamic electric resistor change and welding process heat effect, the solder joint nucleation process mass change relation of solder joint forming process
Closely, be the online sensing of resistance spot welding quality of welding spot information and assessment provides possibility.
Content of the invention
The present invention is directed to the resistance spot welding of common metal thin-plate structure muterial, provides a kind of electricity based on dynamic resistance curve
Hinder weld nugget quality determining method, the method using the welding current in close relations with solder joint forming process, electrode voltage is
Information source, therefore, testing result is reliable, and testing cost consumption is low, and is 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 based on dynamic resistance curve, the method is welded by resistance spot welding
During the electrode voltage signal curve that arrives of real-time detection and welding current signal curve calculate and obtain the dynamic of solder joint forming process
State resistance change curves, form and average dynamic resistance value using dynamic resistance curve are realized to resistance spot welding welding spot size
Detection with solder joint maximum load capacity and assessment, the step of described detection method is as follows:
(1) to different materials different-thickness, set respectively and be no less than ten bond pads electric currents, welding current persistent period, electricity
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) draw out welding current and the time dependent signal waveform of electrode voltage in computer systems, check ripple
The fluctuation amplitude of shape and the reliability in cycle;
(3) using computer system, division arithmetic is made to electrode voltage signal and welding current signal waveform, and then draw
Obtain solder joint forming process dynamic electric resistor change curve, and calculate acquisition solder joint forming process average dynamic resistance value;
(4) pass through to intercept the diameter that the detection of solder joint cross section obtains above-mentioned each group welding condition welding gained solder joint,
Cut mechanical property tests acquisition solder joint maximum load capacity by drawing;
(5) with calculated average dynamic resistance value as X-axis, to detect the spot size or maximum load capacity obtaining
For Y-axis, draw out relation curve using computer system, and matching obtain average dynamic resistance-spot size mathematical model or
Average dynamic resistance-solder joint maximum load capacity mathematical model;
(6) different-thickness, the standard dynamic resistance curve of different materials are made, and in computer systems according to above-mentioned step
Suddenly set up the resistance spot welding quality of welding spot mathematical model data base of different-thickness, different materials;
(7) according to the quality control standards (QCS) adopting, different-thickness, the resistance spot welding spot size reference of different materials are set
Threshold value and maximum load capacity reference threshold;
(8) during actual welding, the dynamic resistance curve that detection is obtained is compared with standard dynamic resistance curve
Right, to judge solder joint nucleating events;
(9) corresponding mathematical model, the average dynamic resistance value that input detection obtains, computer are called in data base
System calculates and exports spot size value to be detected and maximum load capacity value.
The preparation method of described standard dynamic resistance curve is as follows:
(1) select to weld test piece with the workpiece material of solder joint to be detected with thickness identical, set one group of ripe welding
Technological parameter, carries out resistance spot welding including parameters such as welding current, welding current persistent period, electrode pressures, to welding process
Resistance spot welding process welding current signal in Real-time Collection resistance spot weld secondary loop and electrode voltage signal;
(2) welding current and the time dependent signal waveform of electrode voltage are drawn out in computer systems;
(3) using computer system, division arithmetic is made to electrode voltage signal and welding current signal waveform, and then draw
Obtain solder joint forming process standard dynamic resistance curve.
Described standard dynamic resistance curve should include solder joint nucleation starting stage, growth stage and stabilization sub stage three
Point.
Compare with standard dynamic resistance curve phase, such as solder joint dynamic resistance curve to be detected only has the initial rank of solder joint nucleation
Section, then judge solder joint as non-nucleation;As solder joint dynamic resistance curve to be detected only has solder joint nucleation starting stage, growth stage,
Then judge solder joint as non-sufficient nucleation;As solder joint performance graph to be detected has significant solder joint nucleation starting stage, growth stage
With stabilization sub stage three part, then judge solder joint as sufficient nucleation.
Further, on the premise of judging solder joint as sufficient nucleation, such as computer system calculates the spot size value of output
Or maximum load capacity value be less than corresponding given threshold, then this solder joint be judged as unqualified.
The innovation of the present invention is resistance spot welding process secondary circuit welding current and electrode voltage to real-time monitor
Calculate the dynamic resistance curve change obtaining solder joint forming process as information source, by comparing with standard dynamic resistance curve,
Understand the basic condition of solder joint nucleation, by setting up the pass between average dynamic resistance and spot size, solder joint maximum load capacity
It is model, realize the quick, Non-Destructive Testing to resistance spot welding spot size and maximum load capacity and assessment.
The present invention is applied to welding production scene on-line checking and evaluation resistance spot welding quality of welding spot information.With prior art
Compare, the present invention has advantages below:
(1) the information source welding current being adopted and electrode voltage are in close relations with solder joint forming process, calculate
The dynamic electric resistor arriving is strong with quality of welding spot dependency, makes testing result reliability high;
(2) signal detection system is easily realized, and system design manufacturing cost is more cheap;
(3) quality of welding spot information can be detected fastly, form the assessment to resistance spot welding process and quality, be suitable for
Material ranges wider, practicality is stronger;
(4) detection efficiency is high, and assessment method is simple, and qualitative and quantitative detection combines, and False Rate is low.
Brief description
Fig. 1 is the welding current signal waveform of the low-carbon steel plate resistance spot welding process that embodiment 2 arrives.
Fig. 2 is the electrode voltage signal waveform of the low-carbon steel plate resistance spot welding process that embodiment 2 measures.
Fig. 3 is the dynamic electric resistor change curve of 2 points of forming processes of embodiment.
Fig. 4 is low-carbon steel plate resistance spot welding solder joint nucleation process standard dynamic resistance curve.
Fig. 5 is embodiment 3 workpiece no nucleating surface pattern.
Fig. 6 is the welding current signal waveform of the low-carbon steel plate resistance spot welding process that embodiment 2 detects.
Fig. 7 is the electrode voltage signal waveform of the low-carbon steel plate resistance spot welding process that embodiment 3 measures.
Fig. 8 is the dynamic electric resistor change curve of 3 points of forming processes of embodiment.
Fig. 9 is the nugget macro morphology that the detection of embodiment 3 bad property obtains.
Figure 10 is the welding current signal waveform of the low-carbon steel plate resistance spot welding process that embodiment 4 measures.
Figure 11 is the electrode voltage signal waveform of the low-carbon steel plate resistance spot welding process that embodiment 4 measures.
Figure 12 is the dynamic electric resistor change curve of 4 points of forming processes of embodiment.
Figure 13 is the average dynamic resistance and spot size relation curve set up.
Figure 14 is the average dynamic resistance and solder joint maximum load capacity relation curve set up.
Figure 15 is the nugget macro morphology that the detection of embodiment 4 bad property obtains.
Figure 16 is that the embodiment 4 bad property solder joint that obtains of detection draws and cuts mechanical curves.
Specific embodiment
With reference to specific embodiment, the flesh and blood of the present invention is expanded on further.
Embodiment 1:First, the standard dynamic resistance curve of different-thickness different materials to be made, method is as follows:
(1) welded specimen of the low-carbon steel material thin-slab structure of two pieces of thickness 1mm is selected to be overlapped.Using main weldering
Connecing technological parameter is:Welding current is 5500A, and the welding current persistent period is 0.28s, and electrode pressure is 0.15MPa;
(1) to the resistance spot welding process welding current signal in welding process Real-time Collection resistance spot weld secondary loop and
Electrode voltage signal;
(2) welding current and the time dependent signal waveform of electrode voltage are drawn out in computer systems;
(3) using computer system, division arithmetic is made to electrode voltage signal and welding current signal waveform, and then draw
Obtain solder joint forming process standard dynamic resistance curve, as shown in Figure 1.
As seen from Figure 1, standard dynamic resistance curve includes solder joint nucleation starting stage, growth stage and stabilization sub stage
Three parts.
Embodiment 2:Resistance spot welding quality of welding spot detection to the low-carbon steel plate for 1mm for the thickness
Workpiece to be welded is the overlap joint of the low-carbon steel material thin-slab structure of two pieces of thickness 1mm, the main Welder of employing
Skill parameter is:Welding current is 2000A, and the welding current persistent period is 0.28s, and electrode pressure is 0.15MPa.
In welding, the welding current signal of Real-time Collection resistance spot welding process and electrode voltage signal, painted by analysis software
Go out signal waveforms, respectively as shown in Figures 2 and 3.And then obtain solder joint forming process dynamic electric resistor change curve, as Fig. 4 institute
Show.
Fig. 4 dynamic resistance curve and standard dynamic resistance curve shown in Fig. 1 are compared visible, dynamic shown in Fig. 4
Resistance curve only has unstable nucleation starting stage, and continues up to welding process and terminate.Can judge accordingly, solder joint does not become
Core, then quality of welding spot is unqualified.Fig. 5 show embodiment 1 gained workpiece to be welded no nucleating surface pattern.
This result shows, can more accurately and quickly be realized to resistance spot welding solder joint nucleation using the method for the invention
The non-destructive qualitative detection of quality and assessment.
Embodiment 3:The resistance spot welding quality of welding spot detection of the low-carbon steel material of thickness 1mm
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 3500A, and the welding current persistent period is 0.28s, and electrode pressure is 0.15MPa.
In welding, the welding current signal of Real-time Collection resistance spot welding process and electrode voltage signal, painted by analysis software
Go out signal waveforms, respectively as shown in Figure 6 and Figure 7.And then obtain solder joint forming process dynamic electric resistor change curve, as Fig. 8 institute
Show.
Fig. 8 dynamic resistance curve and standard dynamic resistance curve shown in Fig. 1 are compared visible, dynamic shown in Fig. 8
Resistance curve is only made up of nucleation starting stage and growth stage, and continues up to welding process and terminate.Can judge accordingly, weldering
Point is non-sufficient nucleation, then quality of welding spot is unqualified.Fig. 9 show embodiment 3 gained solder joint cross section nucleation pattern.
This result shows, can more accurately and quickly be realized to resistance spot welding solder joint nucleation using the method for the invention
The non-destructive qualitative detection of quality and assessment.
Embodiment 4:
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 of Real-time Collection resistance spot welding process and electrode voltage signal, painted by analysis software
Go out signal waveforms, respectively as shown in Figure 10 and Figure 11.And then obtain solder joint forming process dynamic electric resistor change curve, such as Figure 12
Shown.Its average dynamic resistance of statistical computation is 107.2u Ω.
Figure 12 dynamic resistance curve and standard dynamic resistance curve shown in Fig. 1 are compared visible, dynamic shown in Figure 12
State resistance curve is made up of complete nucleation starting stage, growth stage and stabilization sub stage three part.Can judge accordingly, solder joint is
Sufficient nucleation.Fig. 9 show embodiment 4 gained solder joint cross section nucleation pattern.
Welded using 15 groups of different welding conditions and tested, wherein, welding current be 4500A~
8000A, electrode pressure is 0.1MPa~0.2MPa, and the welding current persistent period is 0.16s~0.38s.Obtained according to real-time detection
The welding current arriving and electrode voltage, are calculated the dynamic resistance curve that 15 bond pads techniques form solder joint, and then calculate
Obtain corresponding average dynamic resistance value.The solder joint that each group is obtained carries out spot size respectively and maximum load capacity is destructive
Detection.Set up average dynamic resistance with spot size, solder joint maximum load capacity relation curve as shown in Figure 13 and Figure 14.Wherein,
According to the relation in Figure 13, matching obtains average dynamic resistance-spot size mathematical model and is:
D=15.467-0.278R+0.0016R2
According to the relation in Figure 14, average dynamic resistance-solder joint maximum load capacity mathematical model that matching obtains is:
F=-17.863+0.385R-0.0016R2
According to the mathematical model set up, bring into calculating averaging of income differential resistance values to the spot size in embodiment 4
Carry out calculating 4.052mm, measured diameter is 4.014mm, as shown in figure 15, error is 0.95% to solder joint nucleation;Butt welding point is
Large bearing capacity carries out calculating 5.02kN, and actual measurement draws shearing load to be 4.92kN, solder joint destructive detection gained mechanical curves
As shown in figure 16, error is 2.03%.
This result shows, can more accurately and quickly realize to resistance spot welding spot size using the method for the invention
Non-destructive determination detection with maximum load capacity and assessment.
Claims (5)
1. a kind of resistance spot welding quality of welding spot detection method based on dynamic resistance curve, the method was welded by resistance spot welding
The electrode voltage signal curve that in journey, real-time detection arrives and welding current signal curve calculate and obtain the dynamic of solder joint forming process
Resistance change curves, realized to resistance spot welding welding spot size using the form of dynamic resistance curve and average dynamic resistance value and
The detection of solder joint maximum load capacity and assessment, the step of described detection method is as follows:
(1)To different materials different-thickness, set respectively and be no less than ten bond pads electric currents, welding current persistent period, electrode pressure
Force parameter carries out resistance spot welding, to the resistance spot welding process weldering in each welding process Real-time Collection resistance spot weld secondary loop
Connect current signal and electrode voltage signal;
(2)Draw out welding current and the time dependent signal waveform of electrode voltage in computer systems, check waveform
Fluctuation amplitude and the reliability in cycle;
(3)Using computer system, division arithmetic is made to electrode voltage signal and welding current signal waveform, and then drafting obtains
Solder joint forming process dynamic electric resistor change curve, and calculate acquisition solder joint forming process average dynamic resistance value;
(4)Obtain, by intercepting the detection of solder joint cross section, the diameter that above-mentioned each group welding condition welds gained solder joint, pass through
Draw and cut mechanical property tests acquisition solder joint maximum load capacity;
(5)With calculated average dynamic resistance value as X-axis, to detect the spot size obtaining or maximum load capacity as Y
Axle, draws out relation curve using computer system, and matching obtains average dynamic resistance-spot size mathematical model or average
Dynamic electric resistor-solder joint maximum load capacity mathematical model;
(6)Make different-thickness, the standard dynamic resistance curve of different materials, and built according to above-mentioned steps in computer systems
Vertical different-thickness, the resistance spot welding quality of welding spot mathematical model data base of different materials;
(7)According to the quality control standards (QCS) adopting, set different-thickness, the resistance spot welding spot size reference threshold of different materials
With maximum load capacity reference threshold;
(8)During actual welding, the dynamic electric resistor change curve that detection is obtained is compared with standard dynamic resistance curve
Right, to judge solder joint nucleating events;
(9)Corresponding mathematical model, the average dynamic resistance value that input detection obtains, computer system is called in data base
Calculate and export spot size value to be detected and maximum load capacity value.
2. the resistance spot welding quality of welding spot detection method based on dynamic resistance curve according to claim 1, its feature exists
In the preparation method of described standard dynamic resistance curve is as follows:
(1)Select to weld test piece with the workpiece material of solder joint to be detected with thickness identical, set one group of ripe welding procedure
Parameter, carries out resistance spot welding including welding current, welding current persistent period, electrode pressure parameter, welding process is adopted in real time
Resistance spot welding process welding current signal in collection resistance spot weld secondary loop and electrode voltage signal;
(2)Draw out welding current and the time dependent signal waveform of electrode voltage in computer systems;
(3)Using computer system, division arithmetic is made to electrode voltage signal and welding current signal waveform, and then drafting obtains
Solder joint forming process standard dynamic resistance curve.
3. the resistance spot welding quality of welding spot detection method based on dynamic resistance curve according to claim 2, its feature exists
In:Standard dynamic resistance curve should include solder joint nucleation starting stage, growth stage and stabilization sub stage three part.
4. the resistance spot welding quality of welding spot detection method based on dynamic resistance curve according to claim 2, its feature exists
In:Compare with standard dynamic resistance curve phase, such as solder joint dynamic resistance curve to be detected only has the solder joint nucleation starting stage, then sentence
Determining solder joint is non-nucleation;As solder joint dynamic resistance curve to be detected only has solder joint nucleation starting stage, growth stage, then judge weldering
Point is non-sufficient nucleation;As solder joint performance graph to be detected has significant solder joint nucleation starting stage, growth stage and stable rank
Section three parts, then judge solder joint as sufficient nucleation.
5. the resistance spot welding quality of welding spot detection method based on dynamic resistance curve according to claim 3, its feature exists
In:On the premise of judging solder joint as sufficient nucleation, such as computer system calculates spot size value or the maximum load capacity of output
Value be less than corresponding given threshold, then this solder joint be judged as unqualified.
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CN113984837B (en) * | 2021-10-27 | 2024-02-23 | 重庆理工大学 | Welding spot quality detection method for resistance spot welding based on welding spot characteristic information fusion |
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 |
CN114861498B (en) * | 2022-05-18 | 2022-11-18 | 上海交通大学 | Resistance spot welding quality on-line detection method fused with multi-sensing time sequence signal mechanism model |
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