CN115365630A - Method for judging quality of resistance welding spot - Google Patents
Method for judging quality of resistance welding spot Download PDFInfo
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- CN115365630A CN115365630A CN202210663582.6A CN202210663582A CN115365630A CN 115365630 A CN115365630 A CN 115365630A CN 202210663582 A CN202210663582 A CN 202210663582A CN 115365630 A CN115365630 A CN 115365630A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/10—Spot welding; Stitch welding
- B23K11/11—Spot welding
- B23K11/115—Spot welding by means of two electrodes placed opposite one another on both sides of the welded parts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/36—Auxiliary equipment
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/30—Computing systems specially adapted for manufacturing
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Abstract
The invention provides a method for judging quality of a resistance welding spot, which comprises the following steps: collecting welding current and voltage between two electrodes; step two, calculating voltage and welding current to obtain a dynamic resistor R1; taking the dynamic resistor R1 in the last period of time in the welding process as a termination resistor array R2; step four, calculating the average value of the termination resistance array R2 as an average termination resistance R3; and step five, calculating an error e between the average termination resistor R3 and the reference termination resistor R0, wherein the reference termination resistor R0 is a set value, and judging whether the quality of the welding spot is qualified or not according to the error e. The invention has the beneficial effects that: the welding spot quality is automatically detected, the welding spot quality detection efficiency is improved, and the production cost is reduced through nondestructive testing.
Description
Technical Field
The invention belongs to the technical field of resistance welding, and particularly relates to a method for judging the quality of a resistance welding spot.
Background
Resistance spot welding is a widely used method for welding metal parts, especially for welding thin plate parts, such as in automobile manufacturing. The quality of the welding spot is the most central factor for whether the resistance spot welding is qualified, the detection of the nugget size, the tensile and shearing force, the torsion resistance and the like of the welding spot is mainly carried out by a destructive detection method at present, the detection of the quality of the welding spot can be realized only by destructive means such as breaking, dismantling and cutting, the detection efficiency is low, and the production cost is increased due to the damage to the workpiece. In addition, there are also nondestructive tests implemented by ultrasonic testing, but this method requires to apply an ultrasonic coupling agent during the testing process, resulting in low testing efficiency and complexity of the testing process, which in turn results in higher testing cost.
Disclosure of Invention
In view of this, the present invention provides a method for determining quality of a resistance welding spot, so as to solve the problems of low detection efficiency and high detection cost of the current resistance welding spot quality.
In order to achieve the purpose, the technical scheme of the invention is realized as follows:
a method for judging the quality of a resistance welding spot comprises the following steps:
(1) Collecting welding current and voltage between two electrodes;
(2) Calculating voltage and welding current to obtain a dynamic resistance R1;
(3) Taking the dynamic resistor R1 in the last period of time in the welding process as a termination resistor array R2, wherein the time length of the last period of time is 10% -30% of the total welding time;
(4) Calculating the average value of the termination resistance array R2 as an average termination resistance R3;
(5) And calculating an error e between the average termination resistance R3 and the reference termination resistance R0, wherein the reference termination resistance R0 is a set value, and judging whether the welding spot quality is qualified and the loss degree of the electrode according to the error e.
Further, the method for judging the quality of the welding spot comprises the following steps:
comparing the error e calculated in the step (5) with upper and lower limits e1 and e2 of the welding spot quality tolerance, and judging the welding spot quality, wherein the upper and lower limits e1 and e2 of the welding spot quality tolerance are set values, and the judgment standard is as follows:
if the error e is larger than the upper limit welding spot quality tolerance upper limit e1 or e is smaller than the welding spot quality tolerance lower limit e2, judging that the welding spot quality has a problem;
and if the error e is within the range of the upper limit e1 and the lower limit e2 of the welding spot quality tolerance, judging that the welding spot quality is not problematic.
Further, the method for judging the electrode loss further comprises the following specific steps:
comparing the error e calculated in the step (5) with upper and lower limits e3 and e4 of the electrode loss tolerance, and judging the electrode loss condition, wherein the upper and lower limits e3 and e4 of the electrode loss tolerance are set values, and the judgment standard is as follows:
if the error e is larger than the upper limit e3 of the electrode loss tolerance or e is smaller than the lower limit e4 of the electrode loss tolerance, adding 1 on the basis of the current over-limit value N;
if the error e is within the range of the upper limit e3 and the lower limit e4 of the electrode loss tolerance, assigning the current over-limit value N to be 0;
comparing the exceeding limit value N with an electrode loss judgment value N1, judging the electrode loss condition, wherein the electrode loss judgment value N1 is a set value, and the judgment standard is as follows:
if the exceeding limit value N is larger than the electrode loss judgment value N1, judging that the electrode is lost and needing to be replaced;
if the exceeding limit value N is smaller than the electrode loss judgment value N1, the accidental result is judged, the electrode is not lost, and the electrode does not need to be replaced.
Further, the error e in step (5) is calculated by the following formula: e = (R3-R0)/R0.
Further, the upper limit e1 of the welding spot quality tolerance is 5% to 15%, and the lower limit e2 of the welding spot quality tolerance is-15% to-5%.
Further, the upper limit e3 of the electrode loss tolerance is 20% to 40%, and the lower limit e4 of the electrode loss tolerance is-40% to-20%.
Further, the electrode loss determination value N1 has a value between 3 and 10.
Compared with the prior art, the method for judging the quality of the resistance welding spot has the following beneficial effects:
(1) According to the method for judging the quality of the resistance welding spot, the error e between the average termination resistance R3 and the reference termination resistance R0 is calculated, the purpose of judging the welding quality of the welding spot can be realized through the error e, the detection process is rapid, the detection efficiency is improved, and the production cost is reduced.
(2) According to the method for judging the quality of the resistance welding spot, the error e between the average termination resistance R3 and the reference termination resistance R0 is calculated, and the error e is compared with the upper limit e3 and the lower limit e4 of the electrode loss tolerance, so that the purpose of judging the electrode loss degree can be achieved, whether the electrode needs to be replaced or not can be quickly identified, and the working efficiency of welding operation is improved while the welding quality is ensured.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention, illustrate embodiments of the invention and together with the description serve to explain the invention and do not constitute a limitation of the invention. In the drawings:
FIG. 1 is a schematic diagram of resistance distribution during resistance spot welding according to an embodiment of the present invention;
FIG. 2 is a flow chart of solder joint quality determination according to an embodiment of the present invention;
fig. 3 is a schematic diagram of solder joint test resistance distribution according to an embodiment of the present invention.
Detailed Description
It should be noted that the embodiments and features of the embodiments may be combined with each other without conflict.
The present invention will be described in detail below with reference to the embodiments with reference to the attached drawings.
As shown in fig. 1, the resistance distribution during resistance spot welding is mainly divided into 7 parts and exhibits symmetry. The upper resistor RE and the lower resistor RE are electrode resistors, the middle RS is a workpiece resistor, and the RE and the RS are mainly determined by materials and basically unchanged in the welding process; RS/S is contact resistance on the joint surface of the workpiece and is also the position where the nugget is formed, and the resistance bears most of resistance heat and is directly related to the nugget size and the welding spot quality; RE/S is contact resistance of an electrode and a workpiece and is divided into an upper part and a lower part, the resistance is mainly influenced by the electrode loss degree in the welding process, when the electrode is damaged, the RE/S can be greatly improved or reduced, and the change range of the RE/S is far larger than that of RS/S; the dynamic resistance curve is a curve which is obtained by collecting current and voltage between electrodes in the process of one-time welding and further obtaining resistance change between the two electrodes in the welding process according to the ohm law, the resistance curve mainly comprises RE/S and RS/S, therefore, the curve comprises information which can reflect the quality of a welding spot and comprises the electrode loss degree, the curve shows a certain change rule in the process of one-time welding, and for low-carbon steel, the curve is generally a process of firstly reducing, then increasing and then gradually reducing. Resistance spot welding is a complex process of multi-parameter coupling, and brings certain difficulty to judgment of welding spot quality. The resistance curve in the welding process can reflect the state of the welding spot nugget and is related to the size of the nugget, and the size of the nugget directly influences the judgment standards of the welding spot quality such as the tensile force, the torsion resistance and the like of the welding spot, so that the related information of the nugget can be obtained through the analysis of the resistance curve, and the judgment of the welding spot quality is further realized.
As shown in fig. 2, a method for determining the quality of a resistance welding spot, which determines that a voltage sensor, a current sensor and a controller are needed, wherein the voltage sensor and the current sensor are electrically connected with the controller, comprises the following steps:
(1) In the resistance spot welding process, a controller collects welding current through a current sensor, and the controller collects voltage between two electrodes through a voltage sensor;
(2) The controller calculates voltage and welding current to obtain a dynamic resistor R1;
(3) Taking the dynamic resistor R1 in the last period of time in the welding process as a termination resistor array R2;
(4) The controller calculates the average value of the termination resistance array R2 as an average termination resistance R3;
(5) And the controller calculates an error e between the average termination resistor R3 and the reference termination resistor R0, the reference termination resistor R0 is a set value, and whether the quality of the welding spot is qualified is judged through the error e. The purpose of judging the welding quality of the welding spot can be realized through the error e, the detection process is quick, the detection efficiency is improved, and the production cost is reduced.
The step (5) further comprises a welding spot quality judging method, which comprises the following steps: the controller compares the error e calculated in the step (5) with upper and lower limits e1 and e2 of the welding spot quality tolerance to judge the welding spot quality, the upper and lower limits e1 and e2 of the welding spot quality tolerance are set values, and the judgment standard is as follows:
if the error e is larger than the upper limit e1 of the welding spot quality tolerance of the upper limit or e is smaller than the lower limit e2 of the welding spot quality tolerance, judging that the welding spot quality has a problem;
and if the error e is within the range of the upper limit e1 and the lower limit e2 of the welding spot quality tolerance, judging that the welding spot quality is not problematic.
The step (5) further comprises an electrode loss judging method, which comprises the following specific steps:
the controller compares the error e calculated in the step (5) with upper and lower limits e3 and e4 of the electrode loss tolerance, and judges the electrode loss condition, wherein the upper and lower limits e3 and e4 of the electrode loss tolerance are set values, and the judgment standard is as follows:
if the error e is larger than the upper limit e3 of the electrode loss tolerance or e is smaller than the lower limit e4 of the electrode loss tolerance, adding 1 on the basis of the current over-limit value N;
if the error e is within the range of the upper limit e3 and the lower limit e4 of the electrode loss tolerance, assigning the current over-limit value N to be 0;
the controller compares the over-limit value N with an electrode loss judgment value N1, judges the electrode loss condition, takes the electrode loss judgment value N1 as a set value, and has the following judgment standards:
if the exceeding limit value N is larger than the electrode loss judgment value N1, judging that the electrode is lost and needing to be replaced;
if the exceeding limit value N is smaller than the electrode loss judgment value N1, an accidental result is judged, the electrode is not worn, and the electrode does not need to be replaced.
And (3) the value taking time of the dynamic resistor R1 in the step (3) is a period of time near the end of welding, and the duration is 10% -30% of the total welding time. In actual use, the value time of the dynamic resistor R1 can be set according to the material and the welding thickness of the plate with the welding, and the purpose of accurately identifying the quality of the welding spot can be achieved.
The calculation formula of the error e in the step (5) is as follows: e = (R3-R0)/R0. The formula is simple in operation, and the operation on the data can be completed without a complex program.
The upper limit e1 of the welding spot quality tolerance is 5% to 15%, and the lower limit e2 of the welding spot quality tolerance is-15% to-5%. When the device is actually used, the values of the upper limit e1 and the lower limit e2 of the welding spot quality tolerance can be correspondingly adjusted according to the material and the welding thickness of the plate with the welding spot, and the purpose of accurately identifying the welding spot quality can be achieved.
The upper electrode loss tolerance e3 is between 20% and 40%, and the lower electrode loss tolerance e4 is between-40% and-20%. In actual use, the values of the upper and lower limits e3 and e4 of the tolerance of the electrode loss can be correspondingly adjusted according to the material and the welding thickness of the plate with the welding, so that the purpose of accurately identifying the electrode loss can be achieved.
The electrode loss determination value N1 has a value between 3 and 10. The value of the electrode loss judgment value N1 can be correspondingly adjusted according to the material and the welding thickness of the plate with the welding, and the purpose of accurately identifying the electrode loss can be achieved.
At present, the quality of welding spots is judged by utilizing peak values, but the method has certain limitation, has obvious effect on low-carbon steel, and has poor effect on other materials. In the actual process of spot welding, the size of the nugget is subjected to a changing process of reducing from none to some and from small to large, the peak value reflects the value of the maximum nugget in the dynamic changing process, but the nugget is reduced, so the final size of the nugget cannot be reflected, and the measurement of the size of the nugget in the judgment of the quality of the welding spot is the measurement of the final size of the nugget, so that the peak value is used for the quality judgment of the welding spot, and certain defects exist. The resistance curve can present different change rules according to different plates and processes, particularly, the peak value of the resistance curve is particularly large when the metal with a coating or a plating layer is welded, and the peak value is not obviously changed when the quality problem occurs, so that the quality is easily misjudged. Compared with the method for judging the quality of the resistance welding spot, the method for judging the quality of the resistance welding spot can effectively avoid the condition of quality misjudgment by calculating the error e between the average termination resistance R3 and the reference termination resistance R0.
As shown in fig. 3, in the process of predicting the quality analysis result of the welding spot and the electrode loss obtained by the method in the primary electrode welding process, the abscissa in the figure is a time axis, and the time is sequentially backward from left to right, i.e. the time at the leftmost side is 0; according to factors such as the material, the thickness and the process characteristics of the plate, the controller selects the dynamic resistor R1 in the last period of time in the welding process as a termination resistor array R2, the duration is 15% of the total welding duration, and respectively sets e4 to-20%, e2 to-10%, e1 to 13%, e3 to 25% and N1 to 5. Starting the electric welding machine, collecting welding current and voltage between electrodes by a controller through a voltage sensor and a current sensor, and outputting a graph through calculation, wherein a black solid graph in the graph is an error e obtained through calculation each time; wherein the dotted line 0 is a standard line with a resistance deviation of 0 from the standard ending, and the circle is represented as a circle, i.e. the quality of the welding spot is qualified, if the error e is greater than e2 and less than e1, the welding spot can be judged to be qualified only if all the circles are in the figure. In the figure, the error e is larger than e1 or smaller than e2 and smaller than e3 and larger than e4, and the trapezoid is represented, namely the quality of the welding spot is unqualified. An error e which is detected by accident at one time is larger than e3 or smaller than e4, and is represented as a square, but the next error e is smaller than e3 and larger than e4, so that the exceeding limit value N is smaller than the electrode loss judgment value N1 at the moment, the point is not taken as an electrode loss alarm point, and the exceeding limit value N is assigned to be 0 at the next point; when 6 continuous triangles appear, the exceeding limit value N is larger than the electrode loss judgment value N1, the controller can judge that the electrode is lost, and reminds an operator that the electrode is required to be replaced in time; by the method, the quality of the welding spots is detected, and the electrode loss can be evaluated. The method is carried out on line in real time, obviously improves the detection efficiency compared with manual work, and indirectly reduces the production cost of welding operation through nondestructive testing.
Those of ordinary skill in the art will appreciate that the elements and method steps of the examples described in connection with the embodiments disclosed herein may be embodied in electronic hardware, computer software, or combinations of both, and that the components and steps of the examples have been described in a functional general in the foregoing description for the purpose of clearly illustrating the interchangeability of hardware and software. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the implementation. Skilled artisans may implement the described functionality in varying ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the present invention.
In the several embodiments provided in the present application, it should be understood that the disclosed method and system may be implemented in other ways. For example, the division of the above-mentioned units is only a logical function division, and other division manners may be available in actual implementation, for example, a plurality of units or components may be combined or may be integrated into another system, or some features may be omitted, or not executed. The units may or may not be physically separate, and components displayed as units may or may not be physical units, that is, may be located in one place, or may be distributed on a plurality of network units. Some or all of the units can be selected according to actual needs to achieve the purpose of the solution of the embodiment of the present invention.
Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; such modifications and substitutions do not depart from the spirit and scope of the embodiments of the present invention, and they should be construed as being covered by the appended claims and their equivalents.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and should not be taken as limiting the scope of the present invention, which is intended to cover any modifications, equivalents, improvements, etc. within the spirit and scope of the present invention.
Claims (7)
1. A method for judging the quality of a resistance welding spot is characterized by comprising the following steps: the method comprises the following steps:
(1) Collecting welding current and voltage between two electrodes;
(2) Calculating voltage and welding current to obtain a dynamic resistance R1;
(3) Taking the dynamic resistor R1 in the last period of time in the welding process as a termination resistor array R2, wherein the time length of the last period of time is 10% -30% of the total welding time;
(4) Calculating the average value of the termination resistance array R2 as an average termination resistance R3;
(5) And calculating an error e between the average termination resistance R3 and the reference termination resistance R0, wherein the reference termination resistance R0 is a set value, and judging whether the welding spot quality is qualified and the loss degree of the electrode according to the error e.
2. The method for judging the quality of the electric resistance welding spot according to claim 1, wherein the method comprises the following steps: the method for judging the quality of the welding spot comprises the following steps:
comparing the error e calculated in the step (5) with upper and lower limits e1 and e2 of the welding spot quality tolerance, and judging the welding spot quality, wherein the upper and lower limits e1 and e2 of the welding spot quality tolerance are set values, and the judgment standard is as follows:
if the error e is larger than the upper limit welding spot quality tolerance upper limit e1 or e is smaller than the welding spot quality tolerance lower limit e2, judging that the welding spot quality has a problem;
and if the error e is within the range of the upper limit e1 and the lower limit e2 of the welding spot quality tolerance, judging that the welding spot quality is not problematic.
3. The method for judging the quality of the electric resistance welding spot according to claim 1, wherein the method comprises the following steps: the method further comprises an electrode loss judgment method, which comprises the following steps:
comparing the error e calculated in the step (5) with upper and lower limits e3 and e4 of the electrode loss tolerance, and judging the electrode loss condition, wherein the upper and lower limits e3 and e4 of the electrode loss tolerance are set values, and the judgment standard is as follows:
if the error e is larger than the upper limit e3 of the electrode loss tolerance or e is smaller than the lower limit e4 of the electrode loss tolerance, adding 1 on the basis of the current over-limit value N;
if the error e is within the range of the upper limit e3 and the lower limit e4 of the electrode loss tolerance, assigning the current over-limit value N to be 0;
comparing the exceeding limit value N with an electrode loss judgment value N1, judging the electrode loss condition, wherein the electrode loss judgment value N1 is a set value, and the judgment standard is as follows:
if the exceeding limit value N is larger than the electrode loss judgment value N1, judging that the electrode is lost and needing to be replaced;
if the exceeding limit value N is smaller than the electrode loss judgment value N1, the accidental result is judged, the electrode is not lost, and the electrode does not need to be replaced.
4. The method for judging the quality of the electric resistance welding spot according to claim 1, wherein the method comprises the following steps: the calculation formula of the error e in the step (5) is as follows: e = (R3-R0)/R0.
5. The method for judging the quality of the electric resistance welding spot according to claim 2, wherein: the upper limit e1 of the welding spot quality tolerance is 5% to 15%, and the lower limit e2 of the welding spot quality tolerance is-15% to-5%.
6. A method of determining the quality of a resistance weld according to claim 3, characterized in that: the upper limit e3 of the electrode loss tolerance is 20% to 40%, and the lower limit e4 of the electrode loss tolerance is-40% to-20%.
7. A method of determining the quality of a resistance weld according to claim 3, characterized in that: the electrode loss determination value N1 has a value between 3 and 10.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202110742345.4A CN113600986A (en) | 2021-06-30 | 2021-06-30 | Method for judging quality of resistance welding spot |
| CN2021107423454 | 2021-06-30 |
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| CN115365630B CN115365630B (en) | 2023-08-04 |
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| CN202210663582.6A Active CN115365630B (en) | 2021-06-30 | 2022-06-13 | Method for judging quality of welding spot of resistance welding |
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Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4493965A (en) * | 1983-05-25 | 1985-01-15 | General Motors Corporation | Method and apparatus for predicting and controlling the quality of a resistance spot weld |
| US4694135A (en) * | 1986-07-09 | 1987-09-15 | General Motors Corporation | Method and apparatus for monitoring and controlling resistance spot welding |
| JPS63137586A (en) * | 1986-11-27 | 1988-06-09 | Miyachi Electric Co | Device for controlling resistance welding |
| CN101201339A (en) * | 2006-12-13 | 2008-06-18 | 天津科技大学 | Apparatus and method for monitoring resistance spot welding quality |
| CN101323047A (en) * | 2008-07-24 | 2008-12-17 | 上海交通大学 | Resistance spot welding quality control device and method based on electrode displacement |
| KR20170076293A (en) * | 2015-12-24 | 2017-07-04 | 주식회사 조웰 | Spot welding quality inspection system |
-
2021
- 2021-06-30 CN CN202110742345.4A patent/CN113600986A/en not_active Withdrawn
-
2022
- 2022-06-13 CN CN202210663582.6A patent/CN115365630B/en active Active
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4493965A (en) * | 1983-05-25 | 1985-01-15 | General Motors Corporation | Method and apparatus for predicting and controlling the quality of a resistance spot weld |
| US4694135A (en) * | 1986-07-09 | 1987-09-15 | General Motors Corporation | Method and apparatus for monitoring and controlling resistance spot welding |
| JPS63137586A (en) * | 1986-11-27 | 1988-06-09 | Miyachi Electric Co | Device for controlling resistance welding |
| CN101201339A (en) * | 2006-12-13 | 2008-06-18 | 天津科技大学 | Apparatus and method for monitoring resistance spot welding quality |
| CN101323047A (en) * | 2008-07-24 | 2008-12-17 | 上海交通大学 | Resistance spot welding quality control device and method based on electrode displacement |
| KR20170076293A (en) * | 2015-12-24 | 2017-07-04 | 주식회사 조웰 | Spot welding quality inspection system |
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| CN115365630B (en) | 2023-08-04 |
| CN113600986A (en) | 2021-11-05 |
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