CN115365630B - Method for judging quality of welding spot of resistance welding - Google Patents
Method for judging quality of welding spot of resistance welding Download PDFInfo
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- CN115365630B CN115365630B CN202210663582.6A CN202210663582A CN115365630B CN 115365630 B CN115365630 B CN 115365630B CN 202210663582 A CN202210663582 A CN 202210663582A CN 115365630 B CN115365630 B CN 115365630B
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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 the quality of a resistance welding spot, which comprises the following steps: step one, collecting welding current and voltage between two electrodes; step two, calculating voltage and welding current to obtain a dynamic resistor R1; step three, taking the dynamic resistance R1 in the last period of time in the welding process as a termination resistance array R2; step four, calculating the average value of the termination resistor array R2 as an average termination resistor R3; and fifthly, 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 through the error e. The invention has the beneficial effects that: the automatic detection of the quality of the welding spots improves the efficiency of the quality detection of the welding spots, and the nondestructive test reduces the production cost.
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 welding spot of resistance welding.
Background
Resistance spot welding is a widely used welding method for joining metal parts, particularly in the welding of sheet metal parts, such as in the automotive manufacturing process. The quality of the welding spot is the most core element of whether the resistance spot welding is qualified or not, the measurement of the nugget size, the tensile shear force, the torsion resistance and the like of the welding spot is mainly detected by a lossy detection method at present, the detection of the quality of the welding spot can be realized by destructive means such as breaking, disassembly, cutting and the like, the detection efficiency is low, the workpiece is damaged, and the production cost is also increased. In addition, there are nondestructive tests performed by ultrasonic testing, but this method requires smearing an ultrasonic couplant during the testing process, resulting in low testing efficiency, and complexity of testing procedures, which in turn results in higher testing cost.
Disclosure of Invention
In view of the above, the present invention aims to provide a method for determining quality of a welding spot of a resistance welding, so as to solve the problems of low quality detection efficiency and high detection cost of the current welding spot of the resistance welding.
In order to achieve the above 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 the voltage and the welding current to obtain a dynamic resistance R1;
(3) Taking a 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 resistor array R2 as an average termination resistor R3;
(5) And 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 and the loss degree of the electrode according to the error e.
Further, the method for judging the quality of the welding spots is further included, and specifically 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, judging the welding spot quality, wherein the upper and lower limits e1 and e2 of the welding spot quality tolerance are set values, and judging standards are 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 is problematic;
if the error e is within the upper limit e1 and the lower limit e2 of the welding spot quality tolerance, the welding spot quality is judged to be free of problems.
Further, the method for judging the electrode loss is further included, and specifically comprises the following steps:
comparing the error e calculated in the step (5) with upper and lower limits e3 and e4 of electrode loss tolerance, judging the electrode loss condition, wherein the upper and lower limits e3 and e4 of the electrode loss tolerance are set values, and judging the electrode loss tolerance 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 exceeding limit N;
if the error e is within the upper electrode loss tolerance limit e3 and the lower electrode loss tolerance limit e4, the current super-limit value N is assigned to 0;
comparing the over-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 judging value N1, judging that the electrode is lost, and replacing the electrode is needed;
if the exceeding 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 calculation formula of the error e in the step (5) is as follows: e= (R3-R0)/R0.
Further, the upper limit e1 of the welding spot quality tolerance is between 5% and 15%, and the lower limit e2 of the welding spot quality tolerance is between-15% and-5%.
Further, the upper limit e3 of the electrode loss tolerance is between 20% and 40%, and the lower limit e4 of the electrode loss tolerance is between-40% and-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 welding spot of the resistance welding, disclosed by the invention, the error e between the average termination resistor R3 and the reference termination resistor 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 welding spot of the resistance welding, disclosed by the invention, the error e between the average termination resistor R3 and the reference termination resistor R0 is calculated, and the error e is compared with the upper limit and the lower limit e3 and the lower limit e4 of the electrode loss tolerance, so that the purpose of judging the electrode loss degree can be realized, whether the electrode needs to be replaced or not can be rapidly identified, the welding quality is ensured, and meanwhile, the working efficiency of welding operation is improved.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the invention. In the drawings:
FIG. 1 is a schematic diagram of a resistance distribution during resistance spot welding according to an embodiment of the present invention;
FIG. 2 is a flowchart of a weld quality determination according to an embodiment of the present invention;
FIG. 3 is a diagram illustrating a distribution of solder joint test resistances according to an embodiment of the present invention.
Detailed Description
It should be noted that, without conflict, the embodiments of the present invention and features of the embodiments may be combined with each other.
The invention will be described in detail below with reference to the drawings in connection with embodiments.
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 resistor RS is a workpiece resistor, RE and RS are mainly determined by materials and are basically unchanged in the welding process; RS/S is the contact resistance on the joint surface of the workpiece and the workpiece, and is also the position where the nugget is formed, and the resistance bears most resistance heat and is directly related to nugget size and welding spot quality; RE/S is the contact resistance of the electrode and the 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 lifted or lowered in a large range, and the change range of the RE/S is far larger than that of the RS/S; the dynamic resistance curve is a curve about the resistance change between two electrodes in a welding process by collecting current and voltage between the electrodes in a one-time welding process and further obtaining a curve about the resistance change between the two electrodes in the welding process by ohm law, wherein the resistance curve mainly comprises RE/S and RS/S, so that the curve comprises information capable of reflecting the quality of welding spots including the electrode loss degree, and the curve presents a certain change rule in a single welding process, and is a process of reducing and then increasing and then gradually reducing for low-carbon steel. Resistance spot welding is a complex process of multi-parameter coupling, and certain difficulty is brought to the judgment of the quality of welding spots. The resistance curve in the welding process can reflect the state of the nugget of the welding spot and is related to the nugget size, and the nugget size directly influences the judgment standard of the welding spot quality such as the tensile shear force, the torsion resistance and the like of the welding spot, so that the relevant information of the nugget can be obtained through 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 welding spot of resistance welding 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, and the method comprises the following steps:
(1) In the resistance spot welding process, a controller collects welding current through a current sensor, and a controller collects voltage between two electrodes through a voltage sensor;
(2) The controller calculates the voltage and the welding current to obtain a dynamic resistance R1;
(3) Taking a 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 resistor array R2 as an average termination resistor R3;
(5) 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 or not is judged through the error e. The purpose of judging the welding quality of the welding spots can be achieved through the error e, the detection process is rapid, the detection efficiency is improved, and the production cost is reduced.
The step (5) also 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, judges the welding spot quality, and the upper and lower limits e1 and e2 of the welding spot quality tolerance are set as values, and the judging 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 is problematic;
if the error e is within the upper limit e1 and the lower limit e2 of the welding spot quality tolerance, the welding spot quality is judged to be free of problems.
The step (5) also comprises an electrode loss judging method, which comprises the following 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, judges the electrode loss condition, and judges the upper and lower limits e3 and e4 of the electrode loss tolerance as set values, wherein 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 exceeding limit N;
if the error e is within the upper electrode loss tolerance limit e3 and the lower electrode loss tolerance limit e4, the current super-limit value N is assigned to 0;
the controller compares the over-limit value N with an electrode loss judgment value N1 to judge 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 judging value N1, judging that the electrode is lost, and replacing the electrode is needed;
if the exceeding 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.
And (3) the value time of the dynamic resistor R1 is a period of time when welding is close to the end, and the duration is 10% -30% of the total welding time. When in actual use, the value time of the dynamic resistor R1 can be set according to the material and the welding thickness of the welded plate, and the purpose of accurately identifying the quality of welding spots 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 to operate, and the operation on the data can be completed without a complex program.
The upper limit e1 of the weld quality tolerance is between 5% and 15%, and the lower limit e2 of the weld quality tolerance is between-15% and-5%. When in actual use, the values of the upper limit e1 and the lower limit e2 of the welding quality tolerance can be correspondingly adjusted according to the material and the welding thickness of the welded plate, and the purpose of accurately identifying the welding 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%. When in actual use, the values of the upper and lower limits e3 and e4 of the electrode loss tolerance can be correspondingly adjusted according to the material and the welding thickness of the welded plate, so that the purpose of accurately identifying the electrode loss can be achieved.
The electrode loss determination value N1 has a value of between 3 and 10. The electrode loss determination value N1 can be correspondingly adjusted according to the material and the welding thickness of the welded plate, and the purpose of accurately identifying the electrode loss can be achieved.
At present, a mode of judging the quality of a welding spot by using a peak value exists, but the method has certain limitation, has obvious effect on low-carbon steel, and has poor effect on other materials. Since the nugget size can undergo a change from none to large and from small to large in the actual process of spot welding, the peak value reflects the numerical value of the nugget in the process of dynamic change when the nugget is maximum, but the nugget is also reduced, so that the final size of the nugget cannot be reflected, and the measurement about the nugget size in the determination of the quality of the welding spot is not only the measurement about the final size of the nugget, so that the quality determination of using the peak value for the welding spot has a certain defect. The resistance curve can show different change rules according to different plates and processes, particularly, the peak value of the resistance curve is very large when the metal with a coating or a plating layer is welded, and the peak value change is not obvious when quality problems occur, so that quality misjudgment is easy to cause. Compared with the method for judging by utilizing the peak value, the method for judging the quality of the resistance welding spot can effectively avoid the condition of misjudgment of the quality by calculating the error e between the average termination resistor R3 and the reference termination resistor R0.
As shown in fig. 3, in the process of primary electrode welding, the quality analysis result of the welding spot and the process of electrode loss prediction obtained by the method are shown, the abscissa in the figure is a time axis, and the time from left to right is sequentially backward, namely the leftmost time is 0; according to the factors of the material, thickness, process characteristics and the like of the plate, the controller selects a 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 e4 is-20%, e2 is-10%, e1 is 13%, e3 is 25%, and N1 is 5. Starting an electric welding machine, collecting welding current and voltage between electrodes by a controller through a voltage sensor and a current sensor, and calculating an output pattern, wherein a black solid pattern in the pattern is an error e obtained by calculation each time; the broken line 0 is a standard line with the deviation of 0 from the standard end resistance, the error e is larger than e2 and smaller than e1 in the figure, namely, the quality of the welding spot is qualified, and only the figures are all round, the welding spot can be judged to be qualified. Errors e greater than e1 or less than e2 and less than e3 greater than e4 are indicated as trapezoids, i.e. spot weld quality failure. An error e detected by accident at one time is larger than e3 or smaller than e4, and is represented as square, but the next error e is smaller than e3 and larger than e4, so that the over-limit value N is smaller than the electrode loss judgment value N1 at the moment, the point is not used as an electrode loss alarm point, and the over-limit value N is assigned as 0 at the next point; when 6 continuous triangles appear, the super-limit value N is larger than the electrode loss judging value N1, the controller can judge that the electrode is lost, and the operator is reminded of timely replacing the electrode; by the method, not only is the welding quality detected, but also the electrode loss can be estimated. The method is carried out on line in real time, and compared with manual work, the method obviously improves the detection efficiency, and the nondestructive test indirectly reduces the production cost of welding operation.
Those of ordinary skill in the art will appreciate that the elements and method steps of each example described in connection with the embodiments disclosed herein may be implemented as electronic hardware, computer software, or combinations of both, and that the elements and steps of each example have been described generally in terms of functionality in the foregoing description to clearly illustrate this 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 solution. 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 this application, it should be understood that the disclosed methods and systems may be implemented in other ways. For example, the above-described division of units is merely a logical function division, and there may be another division manner when actually implemented, 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 performed. The units may or may not be physically separate, and components shown as units may or may not be physical units, may be located in one place, or may be distributed over a plurality of network units. Some or all of the units may be selected according to actual needs to achieve the purpose of the embodiment of the present invention.
Finally, it should be noted that: the above embodiments are only for illustrating the technical solution of the present invention, and not for limiting the same; although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some or all of the technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit of the invention, and are intended to be included within the scope of the appended claims and description.
The foregoing description of the preferred embodiments of the invention is not intended to be limiting, but rather is intended to cover all modifications, equivalents, alternatives, and improvements that fall within the spirit and scope of the invention.
Claims (4)
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 the voltage and the welding current to obtain a dynamic resistance R1;
(3) Taking a 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 resistor array R2 as an average termination resistor R3;
(5) 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 a welding spot is qualified or not and the loss degree of an electrode according to the error e;
the method for judging the quality of the welding spots is also included, and specifically 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, judging the welding spot quality, wherein the upper and lower limits e1 and e2 of the welding spot quality tolerance are set values, and judging standards are 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 is problematic;
if the error e is within the upper limit e1 and the lower limit e2 of the welding spot quality tolerance, judging that the welding spot quality is free of problems;
the method for judging the electrode loss is further included, and specifically comprises the following steps:
comparing the error e calculated in the step (5) with upper and lower limits e3 and e4 of electrode loss tolerance, judging the electrode loss condition, wherein the upper and lower limits e3 and e4 of the electrode loss tolerance are set values, and judging the electrode loss tolerance 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 exceeding limit N;
if the error e is within the upper electrode loss tolerance limit e3 and the lower electrode loss tolerance limit e4, the current super-limit value N is assigned to 0;
comparing the over-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 judging value N1, judging that the electrode is lost, and replacing the electrode is needed;
if the exceeding limit value N is smaller than the electrode loss judging value N1, judging that the electrode is accidental, wherein no loss occurs to the electrode, and the electrode does not need to be replaced;
the calculation formula of the error e in the step (5) is as follows: e= (R3-R0)/R0.
2. The method for determining the quality of a resistance welding spot according to claim 1, wherein: the upper limit e1 of the welding spot quality tolerance is between 5% and 15%, and the lower limit e2 of the welding spot quality tolerance is between-15% and-5%.
3. The method for determining the quality of a resistance welding spot according to claim 1, wherein: the upper electrode loss tolerance e3 is between 20% and 40%, and the lower electrode loss tolerance e4 is between-40% and-20%.
4. The method for determining the quality of a resistance welding spot according to claim 1, wherein: the electrode loss determination value N1 has a value between 3 and 10.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| 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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| CN115365630A CN115365630A (en) | 2022-11-22 |
| CN115365630B true 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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| CN115365630A (en) | 2022-11-22 |
| CN113600986A (en) | 2021-11-05 |
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