JP5053959B2 - Electrode tip contact area ratio evaluation method, workpiece internal resistance evaluation method, ultrasonic attenuation rate evaluation method, and electrode tip tilt state determination method - Google Patents

Description

  The present invention relates to a method for evaluating a contact area ratio of an electrode tip when resistance welding is performed using an electrode tip, a method for evaluating an internal resistance of a workpiece, a method for evaluating an ultrasonic attenuation factor, and a method for determining an inclination state of an electrode tip.

  As is well known, spot welding, which is a method of welding, sandwiches workpieces in contact with each other with a pair of electrode tips, and welds the workpieces in a dot shape by energizing between these electrode tips. To do.

  Spot welding is performed by, for example, a welding gun disposed at the tip of an arm portion of a robot capable of teaching. That is, the robot that has been taught in advance operates so that a workpiece is inserted between the electrode tips provided in the openable / closable clamp part of the welding gun, and then the clamp part is closed. The workpiece is held between the electrode tips. In this state, electricity is applied between the electrode tips, and a melted part is generated in the workpiece. Eventually, as the melted portion solidifies, a spot-like welded portion is formed on the workpiece.

  In spot welding performed in this way, it may be inspected at what timing the melted portion generated in the workpiece grows and solidifies. As this kind of inspection technique, the prior art described in Patent Document 1 is known. That is, this prior art incorporates an ultrasonic oscillator for transmission / reception in one electrode chip, transmits ultrasonic waves from this ultrasonic oscillator, and transmits the ultrasonic waves on the reflective surface provided on the remaining one electrode chip. The reflected ultrasonic waves are received by the ultrasonic oscillator.

Japanese Patent Publication No.59-14189

  When resistance welding is repeatedly performed on a plurality of workpieces, the electrode tips are gradually worn. As a result, the contact area between the electrode tip and the workpiece changes, and accordingly, the area where ultrasonic waves can be transmitted in the electrode tip also changes. In such a situation, in the conventional technique described in Patent Document 1 on the assumption that the contact area between the electrode tip and the workpiece is constant, the detection accuracy of the interface position of the melted part, and consequently the growth rate of the melted part The calculation accuracy will be reduced.

  Further, when evaluating the timing at which the melted portion is growing by implementing the conventional technique described in Patent Document 1, the state in which the electrode tip is inclined with respect to the workpiece because the teaching to the robot is inappropriate. When the robot comes into contact, there is a gap between the growth speed estimated when the robot is properly taught and the measured growth speed. In such a case, since the evaluator cannot know that the electrode tip is in contact with the workpiece in an inclined state, there is a problem that the evaluator cannot evaluate whether the growth rate of the molten part is appropriate. .

  The present invention has been made to solve the above-described problems, and can easily know that the electrode tip is worn or the robot teaching is inappropriate, and can accurately evaluate the change in the state of the workpiece. It is an object of the present invention to provide an electrode tip contact area ratio evaluation method, a workpiece internal resistance evaluation method, an ultrasonic attenuation rate evaluation method, and an electrode tip inclination state determination method that perform evaluation based on the electrode tip contact area ratio evaluation method.

In order to achieve the above object, the present invention provides an electrode tip for obtaining a ratio between the total area of a portion where ultrasonic waves can be incident on the electrode tip for resistance welding and the contact area where the portion contacts the workpiece. The contact area ratio evaluation method of
Obtaining a correlation between the contact area at the part and the incident wave rate of the ultrasonic wave;
Transmitting an ultrasonic wave from an ultrasonic oscillator incorporated in the electrode chip in a state where the electrode chip is separated from the workpiece, and measuring the intensity of the first reflected wave reflected from the tip of the electrode chip;
A step of transmitting an ultrasonic wave from the ultrasonic oscillator in a state where the electrode tip is in contact with the workpiece, and obtaining an intensity of a second reflected wave reflected from a tip of the electrode tip;
Have
After obtaining the reflected wave ratio, which is the intensity ratio of the first reflected wave and the second reflected wave, by the following equation (1), the incident wave ratio, which is the ratio of the incident wave incident on the workpiece, is Obtained by equation (2),
From the incident wave rate and the correlation, a contact area where the part is in contact with the workpiece is obtained, and a contact area ratio is obtained by the following equation (3).
Reflected wave ratio = intensity of second reflected wave / intensity of first reflected wave (1)
Incident wave rate = 1-Reflected wave rate (2)
Contact area ratio = electrode chip contact area / total area where ultrasonic waves can be incident (3)

  By performing such a calculation, it is possible to obtain as information how much of the ultrasonic wave transmitted from the electrode tip is incident on the workpiece. By performing calibration based on this information, it is possible to evaluate how the contact state between the workpiece and the electrode tip changes.

  For example, when the strength ratio and the contact area ratio immediately after the start of resistance welding are repeatedly determined, when the electrode tip is worn, the strength ratio decreases and the contact area ratio increases. By constantly comparing the strength ratio and the contact area ratio, it can be determined whether or not the wear amount of the electrode tip is within an allowable range.

  Note that the correlation between the incident wave rate of ultrasonic waves and the contact area is determined by, for example, transmitting ultrasonic waves from an ultrasonic oscillator incorporated in an electrode chip, obtaining the intensity distribution of the ultrasonic waves, By integrating the intensity distribution in the maximum range in which the intensity is observed to obtain the total area of the ultrasonic incident portion, while repeatedly integrating the intensity distribution within the range in which the ultrasonic intensity is observed Can be sought.

Further, the present invention is an internal resistance evaluation method for evaluating the instantaneous internal resistance of a work that is sandwiched between a pair of electrode tips and subjected to resistance welding,
A step of obtaining a correlation between the total area of the part where the ultrasonic wave can be incident on the electrode tip and the contact area and the incident wave rate of the ultrasonic wave in the part;
Transmitting an ultrasonic wave from an ultrasonic oscillator incorporated in the electrode chip in a state where the electrode chip is separated from the workpiece, and measuring the intensity of the first reflected wave reflected from the tip of the electrode chip;
A step of transmitting an ultrasonic wave from the ultrasonic oscillator in a state where the electrode tip is in contact with the workpiece, and obtaining an intensity of a second reflected wave reflected from a tip of the electrode tip;
Obtaining a total resistance between the set of electrode tips in contact with the workpiece;
Have
After obtaining the reflected wave ratio, which is the intensity ratio of the first reflected wave and the second reflected wave, by the following equation (4), the incident wave ratio, which is the ratio of the incident wave incident on the workpiece, is Obtained by equation (5),
From the incident wave rate and the correlation, after obtaining the contact area where the part is in contact with the work, obtain the contact area ratio by the following formula (6),
Furthermore, the instantaneous internal resistance of the workpiece is obtained by the following equation (7).
Reflected wave ratio = intensity of second reflected wave / intensity of first reflected wave (4)
Incident wave rate = 1- Reflected wave rate (5)
Contact area ratio = electrode chip contact area / total area where ultrasonic waves can be incident (6)
Instantaneous internal resistance = Total resistance between the pair of electrode chips × Contact area ratio (7)

  That is, in this case, the internal resistance of the workpiece is obtained after calibration according to the above information. For this reason, it becomes possible to evaluate the internal resistance of the workpiece more accurately.

  Even in this case, the correlation between the incident wave rate of the ultrasonic wave and the contact area may be obtained as described above.

Furthermore, the present invention is an attenuation rate evaluation method for evaluating an attenuation rate of ultrasonic waves inside a work sandwiched between a first electrode tip and a second electrode tip and being subjected to resistance welding,
An ultrasonic wave is emitted from an ultrasonic oscillator incorporated in the first electrode chip in a state where both the first electrode chip and the second electrode chip are separated from the workpiece, and reflected from the tip of the first electrode chip. Measuring the intensity of the first reflected wave;
The intensity of the second reflected wave that is transmitted from the ultrasonic oscillator in a state where both the first electrode chip and the second electrode chip are in contact with the workpiece, and is reflected from the tip of the first electrode chip. Measuring the intensity of the transmitted wave incident on the receiver incorporated in the second electrode chip, and
Have
After obtaining the reflected wave rate by the following formula (8), the incident wave rate is obtained by the following formula (9),
After obtaining the corrected incident wave intensity of the ultrasonic wave incident on the workpiece by the following formula (10), the corrected transmitted wave intensity is obtained by the following formula (11),
Furthermore, the attenuation rate is obtained by the following equation (12).
Reflected wave ratio = Intensity of second reflected wave / Intensity of first reflected wave (8)
Incidence wave rate = 1-reflection wave rate (9)
Corrected incident wave intensity = Intensity of first reflected wave × incident wave rate (10)
Corrected transmitted wave intensity = transmitted wave intensity / incident wave rate (11)
Attenuation rate = 1-corrected transmitted wave intensity / corrected incident wave intensity (12)

  Ultrasound may be attenuated inside the workpiece. However, according to the present invention, it is possible to obtain the attenuation rate of ultrasonic waves according to the incident wave rate. By taking this attenuation factor into consideration, the state change of the workpiece can be evaluated more accurately.

Furthermore, the present invention is an electrode tip tilt state determination method for determining whether or not the electrode tip is tilted with respect to a workpiece during teaching of a robot having a welding gun having an electrode tip for resistance welding. ,
Transmitting an ultrasonic wave from an ultrasonic oscillator incorporated in the electrode chip in a state where the electrode chip is separated from the workpiece, and measuring the intensity of the first reflected wave reflected from the tip of the electrode chip;
After the ultrasonic wave is transmitted from the ultrasonic oscillator in a state where the electrode tip is in contact with the workpiece from the vertical direction, the intensity of the second reflected wave reflected from the tip of the electrode chip is obtained, Examining the change over time in the reflected wave ratio, which is the intensity ratio between the first reflected wave and the second reflected wave, obtained by the equation (13);
Have
When the electrode tip of the robot on which the teaching was made contacted the workpiece, the time-dependent change in the reflected wave ratio was examined. When the electrode tip is judged to be tilted with respect to the workpiece when the reduction rate of the reflected wave ratio when contacting is small compared to the decrease with time, while the decrease width of the change with time coincides with each other It is determined that the electrode tip is in contact with the workpiece from a vertical direction.
Reflected wave ratio = Intensity of second reflected wave / Intensity of first reflected wave (13)

  According to the present invention, teaching to a robot provided with a welding gun is performed by examining the change over time of the decrease width of the intensity ratio (reflected wave rate) or the difference in the ultrasonic value when the electrode tip contacts the workpiece. It is also possible to determine whether or not is appropriate. That is, when teaching with respect to the robot is appropriate, when the resistance welding proceeds, the contact area of the electrode tip with the workpiece increases because the electrode tip is embedded in the workpiece. For this reason, since it becomes easy for an ultrasonic wave to inject into a workpiece | work, the said intensity ratio falls large with progress of time.

  On the other hand, teaching to the robot is not appropriate, so if the electrode tip comes into contact with the workpiece in an inclined state, ultrasonic waves are incident even if resistance welding progresses and the electrode tip is embedded in the workpiece. Only a part of the possible part is embedded, and there is a part that remains in an exposed state. For this reason, even if time passes, the fall range of the said intensity ratio is small.

  In this way, it is possible to determine whether or not teaching to the robot is appropriately performed by comparing the decrease widths.

  According to the present invention, it is first calculated how much of the ultrasonic wave transmitted from the electrode tip is incident on the workpiece, and calibration is performed based on this result. As a result, it is possible to more accurately evaluate changes in the state of the work, such as changes in the internal resistance of the work over time.

  Moreover, for example, when teaching a robot equipped with a welding gun equipped with an electrode tip, it is determined whether the teaching is properly performed by determining whether the electrode tip is inclined. Is possible.

  Hereinafter, preferred embodiments of the method for evaluating the contact area ratio of the electrode tip according to the present invention in relation to the internal resistance evaluation method of the workpiece and the ultrasonic attenuation rate evaluation method will be described in detail with reference to the accompanying drawings. Explained.

  The electrode tip has a part where an ultrasonic wave can be incident on the work when it comes into contact with the work (an incidentable part), and a part where the ultrasonic wave cannot enter even when it comes into contact with the work (a part where it cannot enter) And exist. Further, even if all of the incident possible parts come into contact with the workpiece, not all of the transmitted ultrasonic waves are incident on the workpiece. Therefore, first, the correlation between the contact area of the incidentable part with the workpiece and the incident wave rate of the ultrasonic wave is obtained. How to obtain this correlation will be described with reference to FIGS.

  In FIG. 1, reference numeral 10 is an electrode tip. A transmitter / receiver 12 capable of transmitting and receiving ultrasonic waves is incorporated in the electrode chip 10.

  The electrode tip 10 is pressed against the lower end surface of the medium 18 supported by the supports 14 and 16 with as much pressing force as possible. Note that the sensor 20 is disposed at a position facing the electrode chip 10 on the upper end surface of the medium 18 so as to contact the medium 18. In this case, the center of the electrode chip 10 and the center of the sensor 20 coincide with each other.

  The electrode chip 10 and the sensor 20 are electrically connected to an ultrasonic flaw detector 26 via lead wires 22 and 24. Note that a preamplifier 28 is interposed in the lead wire 24.

  In such a configuration, first, ultrasonic waves are transmitted from the transmitter / receiver 12 in the electrode chip 10. This ultrasonic wave is incident on the medium 18, propagates through the medium 18, and reaches the sensor 20. The preamplifier 28 amplifies the ultrasonic signal that has reached the sensor 20 and sends it to the ultrasonic flaw detector 26 as a signal.

  The ultrasonic flaw detector 26 recognizes the transmitted signal as the intensity of the ultrasonic wave. That is, the intensity of the ultrasonic wave at the center position of the electrode tip 10 is measured.

  Next, the sensor 20 is moved along the direction of the arrow X1 (however, the sensor 20 is not positioned away from the electrode chip 10). Then, the ultrasonic transmission and the intensity measurement are performed at this position.

  Thereafter, the sensor 20 is moved again along the direction of the arrow X1, and the ultrasonic transmission and the intensity measurement are performed also at the position. Similarly, in the direction of the arrow X2, the ultrasonic transmission and the intensity measurement are repeated.

  In this way, the relationship between the distance from the center position of the electrode tip 10 and the intensity of the ultrasonic wave at that position is examined and plotted. An example is shown in FIG. In FIG. 2, 0 on the horizontal axis represents the center position of the electrode tip 10, a positive number represents a distance from the center position in the X1 direction, and a negative number represents a distance from the center position in the X2 direction. On the other hand, the vertical axis represents the echo height, which corresponds to the intensity of the ultrasonic wave.

  From FIG. 2, the site where the distance from the center extends to 8 mm is an incident-possible site where ultrasonic waves can be incident, and the intensity of the transmitted ultrasonic waves decreases as the distance from the center increases. It can be seen that there is a distribution.

  Here, the area is generally obtained by integrating the distance between two points. Similarly in the present embodiment, integration from one end portion to the other end portion of the incident possible portion is integrated. That is, in the example shown in FIG. 2, integration is performed between −8 mm and +8 mm. Thereby, the total area of the part where the electrode chip 10 can be incident on the medium 18 and the ratio of the ultrasonic wave incident on the medium 18 to the total ultrasonic wave (incident wave rate) are obtained.

  For example, if integration is performed between −0.5 mm and +0.5 mm, the contact area and the incident wave rate of the ultrasonic wave 18 in this section are calculated. Similarly, integration is performed within a suitable range such as between −1 mm and +1 mm, between −2 mm and +2 mm, and the contact area and the incident wave rate of the ultrasonic wave on the medium 18 in each zone are obtained.

  If the contact area and the incident wave rate thus obtained are plotted, the curve shown in FIG. 3, that is, the correlation between the contact area of the electrode tip 10 and the incident wave rate of the ultrasonic wave can be obtained.

  Next, a method for evaluating the contact area of the electrode tip with respect to the workpiece using the correlation thus obtained will be described.

  FIG. 4 is a schematic configuration diagram of a main part of a spot welding apparatus 30 which is a resistance welding apparatus. This spot welding device 30 has a welding gun (not shown) that is openable and closable arranged at the tip of an arm portion of a robot (not shown). The electrode tip 32 and the second electrode tip 34 are provided so as to face each other. As shown in FIG. 4, the first electrode chip 32 and the second electrode chip 34 sandwich the two workpieces W1 and W2 stacked on each other. Accordingly, the tip of the first electrode tip 32 contacts the upper workpiece W1, and the tip of the second electrode tip 34 contacts the lower workpiece W2.

  The first electrode chip 32 includes a transceiver 36 capable of transmitting and receiving ultrasonic waves. On the other hand, the second electrode chip 34 incorporates a receiver 38 capable of receiving the ultrasonic waves.

  The transceiver 36 and the receiver 38 are connected to an echo measuring device (not shown). The echo measuring instrument can measure the intensity of the ultrasonic wave (reflected wave) that has returned to the transmitter / receiver 36 and the intensity of the ultrasonic wave (transmitted wave) that has reached the receiver 38.

  In the above configuration, first, the contact area ratio evaluation of the electrode tip is performed as follows.

  First, ultrasonic waves are transmitted from the transmitter / receiver 36 in the first electrode chip 32. At this time, the first electrode tip 32 is not in contact with the workpiece W1. Accordingly, all of the ultrasonic waves reaching the tip of the first electrode chip 32 are reflected by a medium such as air or vacuum having a large difference in acoustic impedance, and return to the transceiver 36 as a first reflected wave. The intensity of the first reflected wave is measured by the echo measuring device.

  Next, when the robot operates, the workpieces W1 and W2 stacked on each other are inserted between the first electrode tip 32 and the second electrode tip 34 of the welding gun. Of course, the welding gun is open at this point, and therefore the first electrode tip 32 and the second electrode tip 34 are spaced apart to the maximum.

  Next, the welding gun is closed, and the tip of the first electrode tip 32 comes into contact with the upper workpiece W1, and the tip of the second electrode tip 34 comes into contact with the lower workpiece W2. That is, the workpieces W1 and W2 are sandwiched between the first electrode chip 32 and the second electrode chip 34.

  Next, a voltage is applied to the first electrode chip 32 and the second electrode chip 34, and energization is performed between the first electrode chip 32 and the second electrode chip 34. Of course, along with this, current passes through the workpieces W1 and W2, and as a result, the interface between the workpieces W1 and W2 is melted. That is, the melting part 40 is generated.

  Simultaneously with the energization, ultrasonic waves are retransmitted from the transmitter / receiver 36. At this time, a part of the ultrasonic waves is incident on the inside of the workpiece W1 from a portion in contact with the workpiece W1 at the tip of the first electrode chip 32. On the other hand, even if it is a part of the first electrode chip 32 where ultrasonic waves can be incident on the work W1 (hereinafter also referred to as an ultrasonic wave incident-possible part), the part that is not in contact with the work W1 is super Sound waves are reflected. Further, even an ultrasonic wave that has reached a portion in contact with the workpiece W1 is partially reflected without being incident on the workpiece W1. A second reflected wave is generated by such reflection and returns to the transceiver 36.

  The second reflected wave is received by the transceiver 36. The echo measuring instrument measures the intensity of the second reflected wave at this time.

From the intensity of the first reflected wave and the intensity of the second reflected wave measured as described above, the intensity ratio is obtained as shown in the following equation (14).
Intensity ratio = Intensity of second reflected wave / Intensity of first reflected wave (14)

  By obtaining this intensity ratio, the reflected wave rate of the ultrasonic wave when the first electrode tip 32 comes into contact with the workpiece W1 is finally obtained.

  Here, for example, even if the welding gun is closed, if the first electrode tip 32 is not in contact with the workpiece W <b> 1 due to a malfunction of the welding gun, all ultrasonic waves are reflected at the tip of the first electrode tip 32. Therefore, the intensity of the second reflected wave is equal to the intensity of the first reflected wave, and the intensity ratio obtained by the above equation (14), in other words, the reflected wave rate is 1.

  On the other hand, when the first electrode tip 32 is in contact with the workpiece W1, ultrasonic waves are incident on the workpiece W1. If the intensity of the second reflected wave is zero, the intensity ratio (reflected wave rate) is zero, so that all of the ultrasonic waves are incident on the workpiece W1. In the present embodiment, in this case, it is evaluated that the ultrasonic incident portion of the first electrode chip 32 is in contact with the workpiece W1 over the entire area, and the total area of the ultrasonic incident portion is the contact area.

  Actually, immediately after the first electrode tip 32 and the second electrode tip 34 are brought into contact with the workpieces W1 and W2 and energization is started, the temperatures of the workpieces W1 and W2 do not increase so much. For this reason, the workpieces W1 and W2 are not softened at this time, and therefore, the first electrode tip 32 only comes into contact with the pole tip. That is, the entire area of the first electrode chip 32 where the ultrasonic wave can be incident is not necessarily in contact with the workpiece W1. As can be understood from this, in particular, immediately after the start of spot welding, the total area and the contact area of the ultrasonic incident portion are not necessarily equal.

Therefore, based on the intensity ratio (reflected wave rate), the incident wave rate of the ultrasonic wave incident on the workpiece W1 is obtained by the following equation (15).
Incident wave rate = 1-intensity ratio
= 1-intensity of second reflected wave / intensity of first reflected wave (15)

  For example, when the intensity of the first reflected wave and the second reflected wave is 100 and 20, respectively, the intensity ratio calculated according to the above equation (14) is 0.2. This means that 20% of the ultrasonic waves transmitted by the transceiver 36 are reflected as the second reflected wave.

  Then, when the incident wave rate is obtained according to the equation (15), it is 0.8. That is, in this case, 80% of the transmitted ultrasonic waves are incident on the workpiece W1.

  Based on this incident wave rate of 80%, the contact area with respect to the workpiece W1 at the tip of the first electrode tip 32 is obtained from the correlation shown in FIG. That is, a horizontal line L is drawn from the position of 80% on the vertical axis in FIG. 3, and then a perpendicular line M is drawn from the intersection of the horizontal line L and the curve toward the horizontal axis. The intersection of the perpendicular M and the horizontal axis is the contact area.

On the other hand, the total area of the incident portion of the first electrode tip 32 is obtained in advance as described above using the electrode tip 10 having the same configuration as that of the first electrode tip 32. Therefore, the contact area ratio is obtained from Equation (16).
Contact area ratio = electrode chip contact area / total area where ultrasonic waves can be incident (16)

  In addition, as can be understood from the equation (16), the contact area ratio is the total area of the ultrasonic incident portion of the first electrode tip 32 and the first electrode tip 32 is in contact with the workpiece W1. It is defined as the ratio with the contact area.

  As described above, in the present embodiment, when a part of the ultrasonic wave is incident on the workpiece W1 and the remaining part is reflected by the tip of the first electrode chip 32, one of the incident possible parts in the first electrode chip 32 is obtained. The part is determined to be separated from the workpiece W1, and evaluation is performed assuming that energization is performed only from the contacted part.

  By performing this evaluation, it is possible to evaluate whether or not the first electrode tip 32 is worn. When the first electrode tip 32 is worn, the strength ratio decreases and the contact area ratio increases. For example, it is possible to determine whether or not the wear amount of the first electrode tip 32 is within an allowable range by comparing the strength ratio and the contact area ratio immediately after the start of spot welding.

  Of course, the strength ratio and the contact area ratio during spot welding are always calculated, and the wear amount of the first electrode tip 32 is within an allowable range when the strength ratio is equal to or greater than a predetermined value, and eventually the contact area ratio is equal to or less than the predetermined value. You may make it determine with having exceeded.

  Further, by performing this evaluation, it is possible to determine whether or not appropriate teaching is performed on the robot. That is, when appropriate teaching is performed on the robot, as shown in FIG. 4, the first electrode tip 32 and the second electrode tip 34 extend in a direction perpendicular to the workpieces W1 and W2. Abut.

  When energization proceeds and the temperatures of the workpieces W1 and W2 rise sufficiently, the workpieces W1 and W2 are softened. As a result, as shown in FIG. 5, the tips of the first electrode tip 32 and the second electrode tip 34 are slightly embedded in the workpieces W1 and W2, and as a result, the contact area of the ultrasonic incident portion with respect to the workpiece W1 is reduced. growing. Therefore, the reflected wave rate obtained by the above equation (14) decreases with time.

  On the other hand, if the teaching is not properly performed on the robot and the first electrode tip 32 and the second electrode tip 34 are inclined with respect to the workpieces W1 and W2 for this reason, the first electrode Even if the tips of the tip 32 and the second electrode tip 34 are embedded in the workpieces W1 and W2, as shown in FIG. 6, the ultrasonic incident possible portion is not embedded. Accordingly, the reduction width of the reflected wave rate becomes small even when time elapses.

  This tendency becomes more prominent as the inclination angle of the first electrode tip 32 with respect to the workpiece W1 increases. Therefore, the relationship between the tilt angle and the change over time of the reduction rate of the reflected wave ratio is recorded in a state where the tilt angle of the first electrode tip 32 with respect to the workpiece W1 is known, and this record and the tilt angle are unknown. An unknown inclination angle can be obtained by referring to the change with time of the reduction width of the reflected wave ratio in a certain spot welding. As a result, it is possible to determine how much the robot teaching should be corrected.

  Further, the instantaneous internal resistance of the workpieces W1 and W2 can be evaluated as follows.

  The resistance in spot welding is the sum of the contact resistance between the first electrode tip 32 and the workpiece W1, the instantaneous internal resistance of the workpieces W1 and W2, and the contact resistance between the second electrode tip 34 and the workpiece W2. Here, as the spot welding progresses, as the contact area of the ultrasonic incident portion increases (see FIG. 5), the contact resistance between the first electrode tip 32 and the workpiece W1, and the second electrode tip 34 and the workpiece. Both contact resistances with W2 are reduced.

Therefore, the instantaneous internal resistance of the workpieces W1 and W2 can be obtained by the following equation (17) based on the contact area ratio obtained according to the above equations (14) to (16).
Instantaneous internal resistance of workpieces W1 and W2 = total resistance between first electrode tip 32 and second electrode tip 34 × contact area ratio (17)

  FIG. 7 is a graph showing the change over time of the total resistance between the first electrode tip 32 and the second electrode tip 34 and the internal resistance of the workpieces W1 and W2 obtained according to the equation (17). As described above, the instantaneous internal resistance of the workpieces W1 and W2 can be accurately evaluated by performing the calibration in consideration of the contact area ratio of the ultrasonic incident portion of the first electrode chip 32.

  The ultrasonic wave may be attenuated inside the workpieces W1 and W2. In this case, it is not easy to perform accurate evaluation without considering the attenuation rate. Therefore, the attenuation rate of the ultrasonic waves in the workpieces W1 and W2 is obtained as follows.

  First, the reflected wave rate is obtained by the above equation (14). If the reflected wave rate obtained in this way is subtracted from 1, that is, if calculation is performed according to Equation (15), the incident wave rate of the ultrasonic wave incident on the workpiece W1 can be obtained.

Next, the corrected incident wave intensity of the ultrasonic wave incident on the workpiece W1 is obtained by the following equation (18).
Corrected incident wave intensity = Intensity of first reflected wave × incident wave rate (18)

Further, the corrected transmitted wave intensity is obtained by the following equation (19).
Corrected transmitted wave intensity = transmitted wave intensity / incident wave rate (19)

  Here, the transmitted wave is an ultrasonic wave transmitted from the transmitter / receiver 36 and transmitted through the workpieces W1 and W2 and received by the receiver 38.

Based on the corrected incident wave intensity and the corrected transmitted wave intensity obtained as described above, the attenuation rate is obtained by the following equation (20).
Attenuation factor = 1−corrected transmitted wave intensity / corrected incident wave intensity (20)

  For example, when the intensity of the first reflected wave is 300, the intensity of the second reflected wave is 60, and the intensity of the transmitted wave is 160, the intensity of the incident wave is 300 while the intensity of the transmitted wave is 160. Therefore, the apparent attenuation factor is 1-160 / 300 = 0.47. However, this attenuation factor does not consider how much of the transmitted ultrasonic wave is incident on the workpiece W1.

On the other hand, according to the above equations (14), (15), (18) to (20),
Reflected wave ratio = 60/300 = 0.2
Incident wave rate = 1-0.2 = 0.8
Corrected incident wave intensity = 300 × 0.8 = 240
Corrected transmitted wave intensity = 160 / 0.8 = 200
Attenuation rate = 1-200 / 240 = 0.17
It becomes.

  As described above, the attenuation rate can be accurately obtained by calculating the attenuation rate in consideration of how much of the transmitted ultrasonic wave is incident on the workpiece W1. Furthermore, by performing evaluation using ultrasonic waves in consideration of the attenuation rate, it is possible to more accurately evaluate changes in internal resistance of the workpieces W1 and W2, changes in the interface position of the melting portion 40, and the like.

It is a schematic block diagram of the measuring apparatus which measures the intensity distribution of an ultrasonic wave. It is a distribution map which shows intensity distribution of the transmitted ultrasonic wave. It is a graph which shows the correlation with the incident wave rate of an ultrasonic wave calculated | required by integrating the intensity distribution of FIG. 2, and a contact area. It is a principal part schematic block diagram of a spot welding apparatus. It is a principal part schematic block diagram which shows the state in which spot welding progressed and the front-end | tip of an electrode tip was embedded in the workpiece | work. It is a principal part schematic block diagram which shows the state embedded in the state which the front-end | tip of the electrode tip inclined with respect to the workpiece | work. It is a graph which shows the time-dependent change of the total resistance before calibration, and the internal resistance of the workpiece | work calculated | required by calibration.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10, 32, 34 ... Electrode tip 12, 36 ... Transmitter / receiver 26 ... Ultrasonic flaw detector 30 ... Spot welding apparatus 38 ... Receiver 40 ... Melting part

Claims (6)

A method for evaluating a contact area ratio of an electrode tip for obtaining a ratio between a total area of a portion where ultrasonic waves can be incident on an electrode tip performing resistance welding and a contact area where the portion contacts a workpiece,
Obtaining a correlation between the contact area at the part and the incident wave rate of the ultrasonic wave;
Transmitting an ultrasonic wave from an ultrasonic oscillator incorporated in the electrode chip in a state where the electrode chip is separated from the workpiece, and measuring the intensity of the first reflected wave reflected from the tip of the electrode chip;
A step of transmitting an ultrasonic wave from the ultrasonic oscillator in a state where the electrode tip is in contact with the workpiece, and obtaining an intensity of a second reflected wave reflected from a tip of the electrode tip;
Have
After obtaining the reflected wave ratio, which is the intensity ratio of the first reflected wave and the second reflected wave, by the following equation (1), the incident wave ratio, which is the ratio of the incident wave incident on the workpiece, is Obtained by equation (2),
A contact area ratio evaluation method for an electrode tip, wherein a contact area where the part is in contact with a workpiece is obtained from the incident wave rate and the correlation, and a contact area ratio is obtained by the following equation (3).
Reflected wave ratio = intensity of second reflected wave / intensity of first reflected wave (1)
Incident wave rate = 1-Reflected wave rate (2)
Contact area ratio = electrode chip contact area / total area where ultrasonic waves can be incident (3) The evaluation method according to claim 1,
By transmitting an ultrasonic wave from an ultrasonic oscillator incorporated in the electrode chip, obtaining an ultrasonic intensity distribution of the ultrasonic oscillator, and then integrating the intensity distribution in the maximum range in which the ultrasonic intensity is observed A method of evaluating a contact area ratio of an electrode tip, wherein the correlation is obtained by repeatedly integrating the intensity distribution within a range in which the intensity of the ultrasonic wave is observed while obtaining the total area of the part. An internal resistance evaluation method for evaluating an instantaneous internal resistance of a work that is sandwiched between a pair of electrode tips and subjected to resistance welding,
A step of obtaining a correlation between the total area of the part where the ultrasonic wave can be incident on the electrode tip and the contact area and the incident wave rate of the ultrasonic wave in the part;
Transmitting an ultrasonic wave from an ultrasonic oscillator incorporated in the electrode chip in a state where the electrode chip is separated from the workpiece, and measuring the intensity of the first reflected wave reflected from the tip of the electrode chip;
A step of transmitting an ultrasonic wave from the ultrasonic oscillator in a state where the electrode tip is in contact with the workpiece, and obtaining an intensity of a second reflected wave reflected from a tip of the electrode tip;
Obtaining a total resistance between the set of electrode tips in contact with the workpiece;
Have
After obtaining the reflected wave ratio, which is the intensity ratio of the first reflected wave and the second reflected wave, by the following equation (4), the incident wave ratio, which is the ratio of the incident wave incident on the workpiece, is Obtained by equation (5),
From the incident wave rate and the correlation, after obtaining the contact area where the part is in contact with the work, obtain the contact area ratio by the following formula (6),
Furthermore, the internal resistance evaluation method of a workpiece | work which calculates | requires the instantaneous internal resistance of a workpiece | work by following formula (7).
Reflected wave ratio = intensity of second reflected wave / intensity of first reflected wave (4)
Incident wave rate = 1- Reflected wave rate (5)
Contact area ratio = electrode chip contact area / total area where ultrasonic waves can be incident (6)
Instantaneous internal resistance = Total resistance between the pair of electrode chips × Contact area ratio (7) The evaluation method according to claim 3,
By transmitting an ultrasonic wave from an ultrasonic oscillator incorporated in the electrode chip, obtaining an ultrasonic intensity distribution of the ultrasonic oscillator, and then integrating the intensity distribution in the maximum range in which the ultrasonic intensity is observed A method for evaluating the internal resistance of a workpiece, wherein the correlation is obtained by repeatedly integrating the intensity distribution within a range in which the intensity of the ultrasonic wave is observed while obtaining the total area of the part. An attenuation rate evaluation method for evaluating an attenuation rate of ultrasonic waves inside a workpiece that is sandwiched between a first electrode tip and a second electrode tip and is subjected to resistance welding,
An ultrasonic wave is emitted from an ultrasonic oscillator incorporated in the first electrode chip in a state where both the first electrode chip and the second electrode chip are separated from the workpiece, and reflected from the tip of the first electrode chip. Measuring the intensity of the first reflected wave;
The intensity of the second reflected wave that is transmitted from the ultrasonic oscillator in a state where both the first electrode chip and the second electrode chip are in contact with the workpiece, and is reflected from the tip of the first electrode chip. Measuring the intensity of the transmitted wave incident on the receiver incorporated in the second electrode chip, and
Have
After obtaining the reflected wave rate by the following formula (8), the incident wave rate is obtained by the following formula (9),
After obtaining the corrected incident wave intensity of the ultrasonic wave incident on the workpiece by the following formula (10), the corrected transmitted wave intensity is obtained by the following formula (11),
Furthermore, the attenuation rate evaluation method of an ultrasonic wave characterized by calculating | requiring an attenuation rate by following formula (12).
Reflected wave ratio = Intensity of second reflected wave / Intensity of first reflected wave (8)
Incidence wave rate = 1-reflection wave rate (9)
Corrected incident wave intensity = Intensity of first reflected wave × incident wave rate (10)
Corrected transmitted wave intensity = transmitted wave intensity / incident wave rate (11)
Attenuation rate = 1-corrected transmitted wave intensity / corrected incident wave intensity (12) An electrode tip tilt state determination method for determining whether or not the electrode tip is tilted with respect to a workpiece during teaching of a robot having a welding gun having an electrode tip for performing resistance welding,
Transmitting an ultrasonic wave from an ultrasonic oscillator incorporated in the electrode chip in a state where the electrode chip is separated from the workpiece, and measuring the intensity of the first reflected wave reflected from the tip of the electrode chip;
After the ultrasonic wave is transmitted from the ultrasonic oscillator in a state where the electrode tip is in contact with the workpiece from the vertical direction, the intensity of the second reflected wave reflected from the tip of the electrode chip is obtained, Examining the change over time in the reflected wave ratio, which is the intensity ratio between the first reflected wave and the second reflected wave, obtained by the equation (13);
Have
When the electrode tip of the robot on which the teaching was made contacted the workpiece, the time-dependent change in the reflected wave ratio was examined. When the electrode tip is judged to be tilted with respect to the workpiece when the reduction rate of the reflected wave ratio when contacting is small compared to the decrease with time, while the decrease width of the change with time coincides with each other It is determined that the electrode tip is in contact with the workpiece from a vertical direction.
Reflected wave ratio = Intensity of second reflected wave / Intensity of first reflected wave (13)

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