EP3108233A1 - Portable matrix phased array spot-weld inspection system - Google Patents
Portable matrix phased array spot-weld inspection systemInfo
- Publication number
- EP3108233A1 EP3108233A1 EP15751432.4A EP15751432A EP3108233A1 EP 3108233 A1 EP3108233 A1 EP 3108233A1 EP 15751432 A EP15751432 A EP 15751432A EP 3108233 A1 EP3108233 A1 EP 3108233A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- probe
- phased array
- ultrasonic
- weld
- welds
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
Classifications
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/22—Details, e.g. general constructional or apparatus details
- G01N29/26—Arrangements for orientation or scanning by relative movement of the head and the sensor
- G01N29/262—Arrangements for orientation or scanning by relative movement of the head and the sensor by electronic orientation or focusing, e.g. with phased arrays
-
- 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
- B23K11/08—Seam welding not restricted to one of the preceding subgroups
-
- 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
-
- 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
- B23K11/16—Resistance welding; Severing by resistance heating taking account of the properties of the material to be welded
-
- 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
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
- B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
-
- 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
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/22—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded
- B23K20/227—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded with ferrous layer
-
- 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
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/22—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded
- B23K20/233—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded without ferrous layer
- B23K20/2336—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded without ferrous layer both layers being aluminium
-
- 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
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/20—Bonding
- B23K26/21—Bonding by welding
-
- 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
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/20—Bonding
- B23K26/32—Bonding taking account of the properties of the material involved
-
- 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
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
- B23K31/125—Weld quality monitoring
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/04—Analysing solids
- G01N29/11—Analysing solids by measuring attenuation of acoustic waves
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/22—Details, e.g. general constructional or apparatus details
- G01N29/225—Supports, positioning or alignment in moving situation
- G01N29/226—Handheld or portable devices
-
- 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
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/006—Vehicles
-
- 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
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/02—Iron or ferrous alloys
- B23K2103/04—Steel or steel alloys
-
- 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
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/08—Non-ferrous metals or alloys
- B23K2103/10—Aluminium or alloys thereof
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/10—Number of transducers
- G01N2291/106—Number of transducers one or more transducer arrays
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/26—Scanned objects
- G01N2291/263—Surfaces
- G01N2291/2638—Complex surfaces
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/26—Scanned objects
- G01N2291/267—Welds
- G01N2291/2672—Spot welding
Definitions
- the present invention relates generally to inspection systems for use in assessing the performance of industrial manufacturing processes, and more specifically to a nondestructive inspection system for assessing the qu ality of resistance spot welds and other weld joints.
- Sheet metal joining processes are widely used in many industries including the aerospace and automotive industries. Among these processes, resistance spot welding is a very common procedure used to join metal sheets because it has high process speed and is easily adopted in mass production lines. Seam welding, weld bonding, adhesive joining, soldering, and brazing have also gained acceptance. The quality control of such joining processes has been recognized as an important issue to manufacturers. The quality of weld joints is affected by the joining process itself and by the design of the joint. Many factors are considered, including metaliurgic reactions, thermal behaviors, chemical composition, starting condition of the base metal, welding and bonding conditions, and the welding and bonding equipment used during the process. Furthermore, the intricate relationship between these factors makes it difficult to control the quality of the weld joint and difficult to inspect the weld joint in a nondestructive manner.
- Acoustic methods are commonly used nondestructive testing methods for various inspection applications. Unlike other nondestructive testing methods, acoustic methods provide both surface and internal information. Moreover, acoustic methods allow for deeper penetration into specimens and higher sensitivity to small discontinuities in a weld joint. Acoustic methods, however, do have limitations. The most significant limitations include the requirement of a skillful operator for using the testing device and analyzing acoustic data, as well as the very- subjective nature of identifying a stuck or cold weld or inadequate bond, such as a kissing bond. Accordingly, the field of ultrasonic nondestructive evaluation (NDE) is in need of a reliable process or technique for identifying poor quality joints in a manner that eliminates the involvement of a skilled operator and the subjective interpretation of test data.
- NDE ultrasonic nondestructive evaluation
- a first portable system for non-destructively characterizing a spot weld includes at least one matrix phased array probe and a body.
- the matrix phased array probe further includes a plurality of ultrasonic transducer elements arranged in a curved array at one end of the probe that are operative to both generate ultrasonic signals and to receive reflections thereof; and a combination of materials for allowing the probe to conform to a contoured surface of the spot weld while enabling sound energy to be transferred directly into the spot weld under test conditions, wherein the combination of materials further includes a flexible membrane mounted on the end of the probe and a fluid filled chamber or solid sound delay material disposed between the membrane and the array.
- the body is designed to be hand-held and further includes an ergonornically designed outer casing; at least one input for connecting to the at least one matrix phased array probe; ultrasonic phased array transmitting and receiving circuitry in electrical communication with the at least one input; a touch screen computer that further includes at least one data processor running software that includes at least one imaging algorithm for processing data received from the probe and generating color coded ultrasonic C-scan images of characterized welds; and at least one monitor for displaying the color coded ultrasonic C-scan images of the characterized welds in real time.
- a second portable system for noii-destructiveiy characterizing a spot weld also includes at least one matrix phased array probe and a body.
- the matrix phased array probe further includes a plurality of ultrasonic transducer elements arranged in a curved array at one end of the probe that are operative to both generate ultrasonic signals and to receive reflections thereof; and a combination of materials for allowing the probe to conform to a contoured surface of the spot weld while enabling sound energy to be transferred directly into the spot weld under test conditions, wherein the combination of materials further includes a flexible membrane mounted on the end of the probe and a fluid filled chamber or solid sound delay material disposed between the membrane and the array.
- the bod)' is designed to be hand-held and further includes an economically designed outer casing having a handle that has been adapted to store the matrix phased array probe; at least one input for connecting to the probe; ultrasonic phased array transmitting and receiving circuitry in electrical communication with the at least one input; a touch screen computer that further includes at least one data processor running software that includes at least one imaging algorithm for processing data received from the probe and generating color coded ultrasonic C-scan images of characterized welds; at least one monitor for displaying the color coded ultrasonic C-scan images of the characterized welds in real time; and at least one rechargeable battery.
- a third portable system for non- destructively characterizing a spot weld also includes at least one matrix phased array probe and a body.
- the matrix phased array probe further includes a plurality of ultrasonic transducer elements arranged in a curved array at one end of the probe, wherein the transducer elements are further arranged into discrete subgroups, wherein each subgroup may be activated independently of the other subgroups and at different time intervals; and wherein the transducer elements are operative to both generate ultrasonic signals and to receive reflections thereof; and a combination of materials for allowing the probe to conform to a contoured surface
- the combination of materials further includes a flexible membrane mounted on the end of the probe and a fluid filled chamber or solid sound delay material disposed between the membrane and the array.
- the body is designed to be hand-held and further includes an ergonomical!y designed outer casing having a handle that has been adapted to store the matrix phased array probe, and at least one arm rest for supporting the body; at least one input for connecting to the probe; ultrasonic phased array transmitting and receiving circuitry in electrical communication with the at least one input; a touch screen computer, wherein the touch screen computer further includes at least one data processor running software that includes at least one imaging algorithm for processing data received from the probe and generating color coded ultrasonic C-scan images of characterized welds, and wherein C-scan images further include average diameter of weld nugget and fused area for each characterized weld; at least one monitor for displaying the color coded ultrasonic C-scan images of the characterized welds in real time; and at least one rechargeable battery.
- FIG. I is a block diagram showing the primary components of a three- dimensional matrix phased array spot weld inspection system in accordance wit an exemplary embodiment of the present invention
- FIGS. 2a-c provide illustrations of test results derived from analyzing a good spot weld using the system of FIG . 1 ;
- FIG. 3 provides a visual representation in A-scan mode of the electronic gates included in the weld inspection system of FIG. 1;
- FIGS. 4a-c provide illustrations of test results derived from analyzing a poor spot weld using the system of FIG. 1 ;
- FIGS. 5a-b provide illustrations of test results derived from analyzing a stuck weld using the system of FIG. 1;
- FIGS. 6a-b illustrate the shape of the 3-D curved probe element as well as various firing sequences for the sub-element groups
- FIGS. 7a ⁇ d provide modeling verification of the benefits of a 3-D curved probe design versus a 2-D flat probe design
- FIG. 8 provides a data flow chart for an exemplary embodiment of the spot weld inspection process of the present invention
- FIG. 9 provides examples of imaging results for various spot weld conditions
- FIG. 10 is a front perspective view of a portable system for non-destruct vely characterizing spot welds, in accordance with an exemplary embodiment of this invention.
- FIG. 11 is a block diagram of the basic functionality of the system of FIG. 10. DETAILED DESCRIPTION OF THE INVENTION
- This invention is also applicable to metals and nonmetals alike and is not limited to fusion welding, but may also be used to examine solid state welds, brazed and soldered joints. Thus, while this method has particular application in the automated analysis of spot welds, it may also be used to evaluate continuous bonds.
- a stuck weld or stuck joint occurs when workpieces (e.g., pieces of sheet metal) are held together by localized fusion at the welding interface, but no weld button or weld nugget has formed as a result of the welding process.
- a stuck weld typically results from heat at the welding interface being insufficient to create nugget growth.
- fusion may occur at certain points of contact between the sheets of metal.
- coatings can melt and refreeze, effectively soldering the parts together. The resulting bonds are often strong enough to hold the workpieces together under light loads, but reasonable force will pull them apart.
- transmitted ultrasonic beams i.e., sound waves
- transmitted ultrasonic beams will not pass through the interface between sheets if no fusion has occurred. If a stuck weld as occurred, resulting in fusion, but no weld nugget, transmitted ultrasonic beams will pass partially though the sheet interface. If a weld nugget has been properly formed, transmitted ultrasonic beams will pass completely through the sheet interface.
- Phased Array Ultrasonic Testing may be used for flaw detection, sizing, and imaging.
- PA UT technology is the ability to modify electronically the acoustic probe characteristics. Probe modifications are performed by introducing time shifts in the signals sent to (pulse) and received from (echo) individual elements of an array probe.
- A-scan, B-sean and C-scan presentations are common formats for collecting and displaying ultrasonic data for purposes of non-destructive evaluation. Each presentation mode provides a means for visualizing and evaluating the region of material being inspected.
- An A-scan is a simple RF waveform presentation showing the time and amplitude of an ultrasonic signal, as commonly provided by conventional ultrasonic flaw detectors and waveform display thickness gages.
- A- scan is an amplitude modulation scan, and as generally applied to pulse echo ultrasonics, horizontal and vertical sweeps are proportional to time or distance and amplitude or magnitude respectively. Thus the location and magnitude of acoustical interface are indicated as to depth below the transducer.
- the relative amount of energy received is plotted along the vertical axis and the elapsed time (which may be related to the sound energy travel time within the material) is displayed along the horizontal axis.
- A-scan display allows the signal to be displayed in its natural radio frequency form (RF) as a fully rectified RF signal or as either the positive or negative half of the RF signal.
- RF radio frequency
- relative discontinuity size can be estimated by comparing the signal amplitude obtained from an unknown reflector to that from a known reflector.
- Reflector depth can be determined by the position of the signal on the horizontal sweep.
- a C-scan from a phased array system involves an ultrasonic probe being physically moved along one axis while the beam electronically scans along the other axis according to the focal law sequence. Signal amplitude or depth data is collected within gated regions of interest. Data is plotted with each focal law progression, using the programmed beam aperture. Utilizing a matrix phased array probe, beam steering can be accomplished in multiple directions.
- an exemplar ⁇ ' embodiment of the present invention provides a nondestructive inspection system for assessing the quality of resistance spot welds.
- spot weld inspection system 10 is operative to assess the quality of weld 12, which is formed at interface 14, which is located between upper sheet 16 and lower sheet 18 (both having a sheet thickness of about 0.6 mm to about 2.0 mm).
- An air gap of about 0.1 mm to about 0,5 mm may be present between upper sheet 16 and lower sheet 18.
- a three-dimensional, matrix phased array probe 100 is placed on the region of upper sheet 16 that is located over the welded area.
- a curved array of ultrasonic elements 106 is used to transmit a plurality of ultrasonic beams 108 into the w r elded area and to capture the associated reflections 110 of those ultrasonic beams.
- Phased array unit 200 is in electrical communication with the plurality of ultrasonic elements 102 through a plurality of signal pathways 202.
- Phased array unit 200 is also in electrical communication with computer 300, which processes incoming ultrasonic data and generates a visual representation of the welded area.
- Probe 100 includes flexible membrane 102, which allows the tip of the probe to conform to the contour of the welded area and fluid filled chamber 104 or solid sound delay material for focusing and steering ultrasonic beams 108. Because flexible membrane 102 is capable of conforming to curved surfaces as shown in FIG.
- the matrix phased array system of this invention is referred to as ' hree-dimensional" as opposed a "two-dimensional” system which uses a probe having a flattened array and a flat tip.
- FIGS. 2a-c provide illustrations of test results derived from analyzing a good spot weld using system 10.
- ultrasonic beams travel completely through weld 12 and interface 14 and reflect back to probe 100 from the backside of lower sheet 18.
- FIG. 2b illustrates diagrammaticaliy the direction and relative strength of each sound wave as it transmits and reflects at interface 14.
- a thinner line represents loss of acoustic energy as the sound wave interacts with interface 14.
- the reflected signals designated as circled 1, 2, and 3 correspond to the peaks shown in the A-scan presented in FIG. 2c.
- signal 2c provides the signals derived from testing in A-scan mode, wherein signal 1 represents the reflection from the top surface of upper sheet 16, signal 2 represents the first full back reflection, and signal 3 represents the second full back reflection.
- the horizontal line drawn through signal 2 represents a surface gate and the horizontal line adjacent to signal 2 represents an interface gate (see discussion below.)
- system 10 Based on the ultrasonic energy transmission and reflection at weld interface 14 and the back side of lower sheet 18, system 10 uses two adjustable electronic gates to filter out ail unwanted reflected signals.
- the two signals that pass through the gates are either the reflected signal from the back side of the second sheet of metal or the reflected signal from the interface of the two sheet metals.
- the first gate is called the "surface gate” and the second gate is called the "interface gate”. This approach differs from the current commercially available systems that utilize an attenuation coefficient compensation method.
- each ultrasonic element in array 106 generates a primary ultrasonic beam and a secondary ultrasonic beam wherein the primary ultrasonic beam is high gain and wherein the secondary ultrasonic beam is low gain; and wherein the primary and secondary ultrasonic beams are fired in within very close proximity to one another (i.e., milliseconds).
- channel 2 is a low amplitude duplicate of channel 1 in each peak.
- the initial time interval shown is measured from the center of the first peak to the surface gate start position.
- the surface gate start position is locked to the first peak of channel 2 plus the initial time interval.
- the interface gate start position is locked to the surface gate start position.
- FIGS. 4a-c provide illustrations of test results derived from analyzing a poor spot weld using system 10.
- FIG. 4a because no weld nugget exists, ultrasonic beams do not travel completely through interface 14, but rather reflect back to probe 100 from interface 14.
- FIG. 4b illustrates diagrammatically the direction and relative strength of each sound wave as it reflects at interface 14.
- a thinner line represents loss of acoustic energy as the sound wave interacts with interface 14.
- the reflected signals designated as circled 1 , 2, 3, 4, and 5 correspond to the peaks shown in the A-sean presented in FIG.
- FIG. 4c provides the signals derived from testing in A-scan mode, wherein signal 1 represents the first reflection from the top surface of upper sheet 16, signal 2 represents the first reflection from interface 14, signal 3 represents the second reflection from interface 14, signal 4 represents the third reflection from interface 14, and signal 5 represents the fourth reflection from interface 14.
- the horizontal line drawn through signal 3 represents the surface gate and the horizontal line drawn though signal 4 represents the interface gate (see discussion above.)
- FIGS. 5a-b provide illustrations of test results derived from analyzing a stuck weld using system 10. Because an incomplete or poorly formed weld exists, ultrasonic beams travel only partially through interface 14, while intermediate echoes appear between the echoes of interface 14 and full back wall reflection.
- FIG. 5a illustrates diagrammatically the direction and relative strength of each sound wave as it transmits and reflects at interface 14. In FIG. 5a, a thinner line represents loss of acoustic energy as the sound wave interacts with interface 14.
- the reflected signals designated as circled 1, 2, 3, 4, and 5 correspond to the peaks shown in the A- scan presented in FIG. 5b, FIG.
- signal 5b provides the signals derived from testing in A-scan mode, wherein signal 2 represents the first reflection from interface 14, signal 3 represents the first full back reflection, signal 4 represents the second reflection from interface 14, and signal 5 represents the second full back reflection.
- the horizontal line drawn through signal 3 represents the surface gate and the horizontal line drawn though signal 4 represents the interface gate (see discussion above.)
- FIGS. 6a-b illustrate the geometry of the curved three-dimensional probe element
- Acoustic probe 100 includes a plurality of ultrasonic transducer elements 106 arranged in a three- dimensional array and having a combination of materials for allowing the probe to conform to the contoured surface of a spot weld while enabling the sound energy to be transferred directly into the spot weld under test.
- An excitation element (phased array unit 200) is coupled to the array and a subset group of transducer elements are combined to send an ultrasonic beam toward a spot weld.
- Each transducer element in a subset group may be pulsed at different time intervals (phase delay) and their individual waves summed to produce a focusing effect of the beam as well as a steering effect.
- Other three-dimensional arrangements are possible for optimizing the performance for specific applications.
- the total number of elements, overall dimension, and operating frequency determine the overall three-dimensional surface contour shape and its operating characteristics and parameters.
- the design of the three-dimensional probe permits inspection of a larger physical area with a smaller probe, thereby allowing for improved probe access as well as a wider coverage area compared to two-dimensional designs.
- the three-dimensional geometrical arrangement provides optimized accuracy and sensitivity in particular regions of the weld joint.
- FIGS. 7a ⁇ d the result of corner elements of the three-dimensional curved probe shown in FIG. 7a illustrates that the beam launch angle is more steered to the normal direction of the typical spot weld indentation when compared to the two-dimensional flat probe case shown in FIG. 7c, There is no noticeable change in the beam quality for the center elements for both three-dimensional (FIG. 7b) and two-dimensional (FIG. 7d) probes.
- the three- dimensional probe extends the coverage area from the built-in curvature of the probe itself. This invention therefore allows inspection of a larger weld area with a smaller probe diameter, allowing improved access. It may also allow use of fewer numbers of elements, reducing overall system cost, while still covering the entire weld area.
- a computerized controller is coupled to acoustic probe 100 and transducer elements 106 for directing transmission of the ultrasonic signals and for summing and receiving responses therefrom.
- the controller is operative to (i) generate and acquire acoustic signals; (ii) detect the surface of the spot weld for each element grouping; (iii) adjust instrument gating to compensate for surface profile and differences in probe orientation; (iv) measure the signal amplitude ratio between responses reflected from the un-bonded areas and areas with good bond; (v) recognize a subset of the responses as being reflected from the un-bonded areas associated with the spot weld and to separate the subset from a remainder of the responses; (vi) measure the extent of the non- deiamination dimensions; and (vii) present a two-dimensional color coded image of non- delamination of the spot weld (see FIG.
- some of the distinct advantages of this invention include: (i) a three-dimensional matrix probe element; (ii) a phase delay with sub- element group to form a beam focusing and steering capability; (iii) conformable membrane (no need for an attenuation correction); and (iv) an image process utilizing electronic gates to filter out unwanted reflections.
- the present invention is assembled into a fully- integrated, portable (i.e., hand-held), battery-operated, non-destructive inspection system that reduces the need for destructive testing of parts and components that include welded or brazed joints.
- This unit includes ultrasonic phased array circuitry that is lower in cost, smaller in size, and has the capability of being battery operated, so that the device is cost effective and portable for a production line usage.
- the system can be used as a tool for checking the integrity of welded products with great cost-saving and efficiency.
- EWI SpotS ight 1 utilizes matrix phased array (MPA) ultrasonic imaging technology to accurately assess the condition of a joint area by visualizing an ultrasonic C-scan image of the inspection area while providing real-time feedback.
- MPA matrix phased array
- This system can be utilized in a wide variety of manufacturing settings for inspection of parts and components made of metals and non- metals. The system is effective for evaluating the quality of various joining configurations including resistance spot welds, resistance seem welds, laser welds, friction stir spot welds, M1G spot welds, brazing, and others.
- This invention is particularly useful for: (i) the automotive industry with regard to evaluating the quality of spot welds for steel, resistance spot welds for steel and aluminum, friction stir spot welds for aluminum, and laser welds for steel; (ii) the
- the portable version of this invention is intended for use as an inspection system in one or more production environments.
- the basic components of this system include: (i) ultrasonic phased array transmitting and receiving circuitry; (ii) a fully-integrated computer with data processing capabilities and imaging algorithm(s); (iii) at least one matrix phased array probe having a quick connect/disconnect electrical connection; and (iv) an economically designed and fully portable case with a carrying handle that provides a safe storage space for the matrix phased array probe therein.
- an exemplary embodiment of portable weld joint inspection unit 400 includes body 410 and handle 424.
- Body 410 further includes power switch 412, side access for USB and external monitor connections 413; screen 414, aluminum plate 416, connector adaptor 417 (e.g., Flypertronix Omni Connector adaptor); cord wrap 418, stylus storage area 420, and arm rest 422.
- Handle 424 further includes probe storage area 426.
- Probe 100 is connected to probe connector 103 (e.g., multi-pin Omni connector), which then connects to weld joint inspection unit 400 at connector adapter 417.
- the ultrasonic phased array transmitting and receiving circuitry further includes 64-channe!
- the computer includes an Intel i7 dual-core powered ruggedized tablet computer running on Windows 7 or Windows 8 operating software with a flat touch screen display that improves inspection speed by eliminating the need for a computer mouse and keyboard in a production environment;
- the imaging aigorithm(s) further includes SpotSightTM imaging software (EWI, Inc.; Columbus, Ohio) for providing the appropriate imaging algorithm to process the data from the phased array electronics;
- the at least one matrix phased array probe further includes a 64-element 3-D matrix phased array probe;
- the ergonomic casing further includes ail features necessary for allowing cooling for the internal electronics, a handle from carrying the instrument, and various features that al low safe storage of the probe and access to all required power and data ports.
- Wireless connectivity e.g., Bluetooth, Wi-Fi, cellular network, etc.
- a rechargeable battery are also typically included.
- the aforementioned aspects of this embodiment effectively confer the following advantageous features to the present invention, (i) the ability to quantitatively assess welds and other types of materials joining with numerical data displayed on the screen; (ii) self-contained non-destructive ultrasonic inspection system; (iii) hand-held portability; (iv) battery power; (v) touch screen and wireless functionalities; and (vi) robust quick eiectrical/mechanical connection of probe to the unit,
- FIG. 11 provides a system block diagram that illustrates the basic functionality of an exemplary embodiment of portable weld joint inspection unit 400.
- phased array electronic circuit 520 activates matrix phased array probe 510 with an activation command from the data processing software.
- ultrasonic signals detected by matrix phased array probe 510 are fed to imaging algorithm 530 to be processed for fused and non-fused conditions of joining area under inspection.
- color coded ultrasonic C-scan image 540 is displayed on the screen with additional numerical data such as average diameter of nugget and fused area.
- EWI SpotSigtit lM processes ultrasonic signals as they are detected by the individual subgroups of the probe array using two gates, one for the front surface reflection and the other for interface reflection.
- An ultrasonic C-scan image is plotted as raw ultrasonic data is processed real time with the dual gate imaging algorithm.
- the feedback time to the operator is fraction of a second and adjustment of the probe is relatively easy and fast compared to systems for which the probe has to be repositioned if results are unsatisfactory.
- several factors can cause undesired variations including: (i) the changing acoustic impedance of an aging membrane; (ii) natural degradation of piezoelectric elements included in the sensor/probe; (iii) slight differences between transducers; and (iv) a natural tendency of the system to undersize all welds.
- some embodiments of this invention include a feature that allows the ratio between the first image gate and the second image gate to be adjusted.
- This feature gives an operator of the system the ability to calibrate the system to welds of known diameter, thereby increasing the overall accuracy of the system.
- the system operator places the probe on a standard which includes a weld nugget having a known or predetermined diameter. If the image reads slightly larger or smaller than the standard, then the gate ratio is adjusted by the operator through specific inputs in the software.
- the image appearing on the screen of portable weld joint inspection unit 400 is created essentially by comparing the signal strength from the first gate to the strength from the second gate.
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Abstract
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Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US14/183,643 US9037419B2 (en) | 2011-05-10 | 2014-02-19 | Portable matrix phased array spot weld inspection system |
PCT/US2015/016042 WO2015126787A1 (en) | 2014-02-19 | 2015-02-16 | Portable matrix phased array spot-weld inspection system |
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EP3108233A1 true EP3108233A1 (en) | 2016-12-28 |
EP3108233A4 EP3108233A4 (en) | 2017-10-04 |
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EP15751432.4A Withdrawn EP3108233A4 (en) | 2014-02-19 | 2015-02-16 | Portable matrix phased array spot-weld inspection system |
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EP (1) | EP3108233A4 (en) |
JP (1) | JP2017509873A (en) |
KR (1) | KR20160122165A (en) |
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WO (1) | WO2015126787A1 (en) |
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US10302600B2 (en) | 2016-01-19 | 2019-05-28 | Northrop Grumman Innovation Systems, Inc. | Inspection devices and related systems and methods |
US11353430B2 (en) * | 2017-03-13 | 2022-06-07 | Baker Hughes Oilfield Operations Llc | Phased array probe and method for testing a spot-weld |
CH713739A2 (en) * | 2017-04-28 | 2018-10-31 | Soudronic Ag | Method and device for roll seam welding of container frames. |
CN109283251B (en) * | 2017-07-19 | 2021-02-09 | 中国科学院声学研究所 | Signal processing circuit of well wall imaging ultrasonic phased array |
KR102007494B1 (en) * | 2017-12-29 | 2019-08-05 | 주식회사 신영 | System for inspecting welding quality of weld zone using ultrasonic |
DE102018213372A1 (en) * | 2018-08-09 | 2020-02-13 | Bayerische Motoren Werke Aktiengesellschaft | Method and device for ultrasonic spot welding |
KR102147178B1 (en) * | 2018-10-02 | 2020-08-24 | 경일대학교산학협력단 | Image processing method and apparatus for spot welding quality evaluation |
JP7215134B2 (en) * | 2018-12-17 | 2023-01-31 | 株式会社島津製作所 | Inspection device and inspection method |
EP3798629A1 (en) * | 2019-09-24 | 2021-03-31 | Kabushiki Kaisha Toshiba | Processing system, processing method, and storage medium |
KR102294189B1 (en) * | 2021-04-16 | 2021-08-27 | 주식회사 성안테크 | Inspection device to detect welding status of missing or folding tab of battery electrode |
CN115740711A (en) * | 2022-11-07 | 2023-03-07 | 苏州固仑光电设备有限公司 | Automatic spot welding and spot welding quality detection system based on visual identification |
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US9037419B2 (en) * | 2011-05-10 | 2015-05-19 | Edison Welding Institute, Inc. | Portable matrix phased array spot weld inspection system |
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- 2015-02-16 KR KR1020167022588A patent/KR20160122165A/en not_active Application Discontinuation
- 2015-02-16 EP EP15751432.4A patent/EP3108233A4/en not_active Withdrawn
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KR20160122165A (en) | 2016-10-21 |
CN106257999A (en) | 2016-12-28 |
WO2015126787A1 (en) | 2015-08-27 |
JP2017509873A (en) | 2017-04-06 |
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