JP5938799B2 - Spot welding quality monitoring method and monitoring apparatus - Google Patents
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- JP5938799B2 JP5938799B2 JP2012202417A JP2012202417A JP5938799B2 JP 5938799 B2 JP5938799 B2 JP 5938799B2 JP 2012202417 A JP2012202417 A JP 2012202417A JP 2012202417 A JP2012202417 A JP 2012202417A JP 5938799 B2 JP5938799 B2 JP 5938799B2
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- 238000003466 welding Methods 0.000 title claims description 59
- 238000000034 method Methods 0.000 title claims description 17
- 238000012544 monitoring process Methods 0.000 title claims description 8
- 230000005856 abnormality Effects 0.000 claims description 5
- 238000012806 monitoring device Methods 0.000 claims description 4
- 230000002159 abnormal effect Effects 0.000 description 4
- 230000007547 defect Effects 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 230000008569 process Effects 0.000 description 4
- 238000010586 diagram Methods 0.000 description 3
- 238000002474 experimental method Methods 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 238000007796 conventional method Methods 0.000 description 2
- 230000002950 deficient Effects 0.000 description 2
- 238000000691 measurement method Methods 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 230000008570 general process Effects 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
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- Investigating Strength Of Materials By Application Of Mechanical Stress (AREA)
Description
本発明は、金属板のスポット溶接品質の監視方法及び監視装置であり、特に溶接時、瞬時に溶接不良を検知できる方法及び装置に関するものである。 The present invention relates to a method and an apparatus for monitoring spot welding quality of a metal plate, and more particularly to a method and apparatus capable of instantaneously detecting a welding failure during welding.
従来、金属板、特に鋼板の結合には、二枚の被溶接物を重ねて、加圧通電し、その抵抗熱で、融接するスポット溶接工法が、種々の製品、例えば、自動車ボディの結合や自動販売機の筐体など、多くの分野で用いられている。 Conventionally, for the joining of metal plates, especially steel plates, spot welding methods in which two workpieces are stacked, pressurized and energized, and fusion-bonded with the resistance heat are used for various products such as joining automobile bodies. It is used in many fields such as the vending machine housing.
スポット溶接の品質を決定する三大条件は「電極加圧力」、「溶接電流」、「通電時間」といわれる。しかし、その他の外部要因、例えば、多くの溶接打点による溶接電極の経時的な形状の変化による接触抵抗の変動や電極の面直度のズレ、被溶接物(材料)の表面状態の不均一性や表面欠陥による接触抵抗等の変動、電極部構造の剛性の劣化などにより、適切な溶接品質が得られず、溶接不良となる問題がある。 The three major conditions that determine the quality of spot welding are said to be "electrode pressure", "welding current", and "energization time". However, other external factors such as variations in contact resistance due to changes in the shape of the welding electrode over time due to many welding points, deviations in electrode surface straightness, and non-uniformity in the surface condition of the work piece (material) Due to variations in contact resistance and the like due to surface defects and deterioration in rigidity of the electrode structure, there is a problem in that appropriate welding quality cannot be obtained, resulting in poor welding.
「溶接電流」及び「通電時間」はスポット溶接機の制御装置で材質や板厚の種々の相違に対応するよう事前に設定された溶接条件が入力されている。「電極加圧力」も当然事前に設定された溶接条件が入力されているが、上記に示した外部要因により被溶接物に対して設定した加圧力が付与されていない状態が発生しているではないか、という疑念がある。これは、溶接スベリといわれる現象が往々に発生し、溶接不良を引き起こしているのと関連性があると推測される。 “Welding current” and “energization time” are input with welding conditions set in advance so as to correspond to various differences in material and plate thickness by the control device of the spot welding machine. Of course, the preset welding conditions are also input for the “electrode pressure”, but there is a situation where the set pressure is not applied to the workpiece due to the external factors described above. There is a suspicion that there is not. This is presumably related to the fact that a phenomenon called welding slip often occurs and causes welding failure.
スポット溶接の品質を検査、監視する方法は、従来から数多く提案されている。
更に近年は難溶接材料の使用が多くなったことによる溶接不良発生の増大のため、更なる溶接品質の監視が必要視されている。
従来のスポット溶接の品質を検査、監視する方法を概して言うと、多くは溶接後の溶融部のナゲット径を計測する手段が多い。その多くは、超音波を透過させ測定する方法である。
超音波での測定方法以外にも、チップ間電圧や、チップ間抵抗を求め、溶接品質の良否を判定する方法などがある。
しかし、スベリ現象など、溶接する過程の不具合に対しての解析や判定する方法はまだ提案されていない。
Many methods for inspecting and monitoring the quality of spot welding have been proposed.
Furthermore, in recent years, further increase in the occurrence of poor welding due to the increased use of difficult-to-weld materials has led to the need for further monitoring of welding quality.
Generally speaking, conventional methods for inspecting and monitoring the quality of spot welding generally have many means for measuring the nugget diameter of the melted portion after welding. Many of them are methods of transmitting ultrasonic waves.
In addition to the ultrasonic measurement method, there is a method for determining the quality of welding quality by obtaining the inter-chip voltage and inter-chip resistance.
However, a method for analyzing and judging defects in the welding process such as slip phenomenon has not been proposed yet.
スポット溶接の品質を検査する従来の事例として下記の特許文献がある。
特許文献1、特許文献2は超音波によるナゲットの測定方法の事例である。
特許文献3には、従来の技術の概要が明示されているが、特許文献3は溶接機に品質監視装置を設置し即座に品質の良否を判定するものである。
これらは、いずれも上記に示した従来の検査方法であり、前述した溶接する過程の不具合に対して判定する方法ではない。
There are the following patent documents as conventional examples for inspecting the quality of spot welding.
Patent Documents 1 and 2 are examples of nugget measurement methods using ultrasonic waves.
Patent Document 3 discloses the outline of the conventional technique. However, Patent Document 3 installs a quality monitoring device in a welding machine and immediately determines quality.
These are all the conventional inspection methods described above, and are not methods for determining the above-described defects in the welding process.
本発明は、スポット溶接での溶接不良を、溶接する過程で検知し、即座に判定できる装置を提供することを目的とする。 An object of this invention is to provide the apparatus which can detect the welding defect in spot welding in the process of welding, and can determine immediately.
本発明は次の構成により上記課題を解決する。
<構成1>
スポット溶接機において、
固定側の下電極にツバ部を設け、前記ツバ部の下面で押圧されるよう2分力計を設置し、
前記2分力計は八角弾性リングの横方向の6箇所の表面と複数の異形孔部に歪ゲージを取り付け、上面の加圧力を2分力Fz、Fyに分解し検知するよう構成し、
一方の分力Fyが、前もって定めた閾値を越えたときに、異常と警告するシステムを備えた、
スポット溶接機の溶接品質監視方法。
The present invention solves the above problems by the following configuration.
<Configuration 1>
In spot welders,
Provide a brim portion on the lower electrode of the fixed side, and install a two-component force meter to be pressed by the lower surface of the brim portion,
The two-component force meter is configured to attach strain gauges to six lateral surfaces of the octagonal elastic ring and a plurality of deformed holes, and to disassemble and detect the applied pressure on the upper surface into two component forces Fz and Fy,
When one component force Fy exceeds a predetermined threshold value, a system is provided that warns that there is an abnormality.
Weld quality monitoring method for spot welders.
<構成2>
スポット溶接機において、
固定側の下電極にツバ部を設け、前記ツバ部の下面で押圧されるよう2分力計を設置し、
前記2分力計は八角弾性リングの横方向の6箇所の表面と複数の異形孔部に歪ゲージを取り付け、上面の加圧力を2分力Fz、Fyに分解し検知するよう構成し、
一方の分力Fyが、前もって定めた閾値を越えたときに、異常と警告するシステムを備えた、
スポット溶接機の溶接品質監視装置。
<Configuration 2>
In spot welders,
Provide a brim portion on the lower electrode of the fixed side, and install a two-component force meter to be pressed by the lower surface of the brim portion,
The two-component force meter is configured to attach strain gauges to six lateral surfaces of the octagonal elastic ring and a plurality of deformed holes, and to disassemble and detect the applied pressure on the upper surface into two component forces Fz and Fy,
When one component force Fy exceeds a predetermined threshold value, a system is provided that warns that there is an abnormality.
Spot welding machine welding quality monitoring device.
スポット溶接は、上下に配置した電極で被溶接物を挟持しつつ、加圧シリンダで所定の圧力で押圧する。直後、制御部に設定された溶接電流が所定の時間だけ印加され、溶接が実施される。その後、加圧が解除されて、溶接1打点が完了する。図1は被溶接物をスポット溶接機で溶接する一般的なスポット溶接工程の説明図である。ここでのスポット溶接機1は特開2012−30283に示すものを用いている。 Spot welding presses with a predetermined pressure with a pressurization cylinder, pinching | interposing a to-be-welded object with the electrode arrange | positioned up and down. Immediately after that, the welding current set in the control unit is applied for a predetermined time, and welding is performed. Thereafter, the pressurization is released, and one welding point is completed. FIG. 1 is an explanatory diagram of a general spot welding process for welding an object to be welded with a spot welder. The spot welding machine 1 here uses what is shown to Unexamined-Japanese-Patent No. 2012-30283.
溶接時の電極のスベリといわれる現象を先に解析するため、図1の下電極を取り外し、図2のように3方向分力計を取り付ける。この3方向分力計は直交する3方向の力Fx、Fy、Fzを計測する計器であり、解析での実験には、精度の高い水晶圧電式の3方向分力計20を用いている。Fx、Fyは垂直な加圧力に対し水平方向の分力、Fzは加圧力と同じ垂直方向の分力であり、図2ではFxは紙面に垂直な方向の分力を示す。
この実験では、上電極と3方向分力計20との位置を溶接機の躯体2から、徐々に離れさせたときの、加圧力を3方向分力計で計測し、そのデータを示したのが、図3である。図3では躯体2からの距離AmmとBmmでの2方向の分力Fx、Fyを表示している。この図から判別されることは、X方向の力が零に近いことである。データを一部しか記載していないが、いずれの場所においても、X方向の力が零に近いことが判明した。
そこで、本発明では零に近い1方向の力Fxの計測は不要と考え、新たに案出する2方向の分力計により、溶接スベリと分力の関連を計測し、更に溶接品質との相関を追及する。本発明は溶接スベリの分力を計測する方法を提案し、また、溶接品質の簡便な監視装置を提供する。
この内容を以下、添付する図を用いて実施例を説明すると、次のとおりである。
In order to first analyze the phenomenon called electrode slippage during welding, the lower electrode in FIG. 1 is removed and a three-way force meter is attached as shown in FIG. The three-direction force meter is a meter that measures forces Fx, Fy, and Fz in three directions orthogonal to each other, and a high-precision crystal piezoelectric three-way force meter 20 is used for an experiment in analysis. Fx and Fy are component forces in the horizontal direction with respect to the vertical pressurizing force, Fz is a component force in the same vertical direction as the pressurizing force, and Fx in FIG. 2 indicates a component force in the direction perpendicular to the paper surface.
In this experiment, when the positions of the upper electrode and the three-way force meter 20 were gradually moved away from the housing 2 of the welding machine, the applied pressure was measured with the three-way force meter, and the data was shown. FIG. In FIG. 3, component forces Fx and Fy in two directions at distances Amm and Bmm from the housing 2 are displayed. What is discriminated from this figure is that the force in the X direction is close to zero. Although only a part of the data is shown, it was found that the force in the X direction was close to zero at any location.
Therefore, in the present invention, it is considered unnecessary to measure the force Fx in one direction close to zero, and the newly developed two-way force meter measures the relationship between welding slip and component force, and further correlates with the welding quality. To pursue. The present invention proposes a method for measuring the component force of welding slip and also provides a simple monitoring device for welding quality.
The contents will be described below with reference to the accompanying drawings.
本発明の実施例1の全体概要が図4である。図4(a)に2分力Fz、Fyを示す。 FIG. 4 shows an overall outline of the first embodiment of the present invention. FIG. 4A shows the two component forces Fz and Fy.
先に説明したように、スポット溶接機1には図4に示すように、図5の2分力計21を配備する。
上電極3が降下して被溶接物Wを押圧すると、2分力計21で分力が計測されシステムとして連動してパソコンの画面に2分力の一方のFyが表示される。これが閾値をこえると異常値として検出される。
As described above, the spot welder 1 is provided with the two-component force meter 21 of FIG. 5 as shown in FIG.
When the upper electrode 3 moves down and presses the workpiece W, the component force is measured by the two-component force meter 21, and one Fy of the two component force is displayed on the personal computer screen in conjunction with the system. If this exceeds the threshold value, it is detected as an abnormal value.
図5(a)、(b)に示す2分力計21ではフレーム部の八角弾性リング22の横の表面6箇所と、2つの異形孔部24の座グリ部分に、各々歪ゲージ23が合計8個取り付けられている。中央の挿入孔25で下電極4を嵌合し図4に示すように組み込む。下電極4のツバ部8は下電極4と一体であり、上電極3が降下して被溶接物Wを押圧すると同時に、ツバ部8の下面が2分力計21の上面を押圧し、八角弾性リング22がたわみ、同時に8箇所の歪ゲージ23がこれを検知する。 In the two-component force meter 21 shown in FIGS. 5 (a) and 5 (b), the strain gauges 23 are totaled at the six horizontal surfaces of the octagonal elastic ring 22 of the frame portion and the counterbore portions of the two deformed hole portions 24, respectively. Eight are attached. The lower electrode 4 is fitted in the central insertion hole 25 and assembled as shown in FIG. The flange portion 8 of the lower electrode 4 is integral with the lower electrode 4. The upper electrode 3 descends and presses the workpiece W. At the same time, the lower surface of the flange portion 8 presses the upper surface of the two-component force meter 21. The elastic ring 22 is bent, and at the same time, the eight strain gauges 23 detect this.
図6はシステム概要を示すブロック図である。
スポット溶接機1に取り付けられた2分力計21の測定値はセンサインターフェイス26を介してPC(パーソナルコンピュータ)27の画面に表示される。
FIG. 6 is a block diagram showing an outline of the system.
The measured value of the two-component force meter 21 attached to the spot welder 1 is displayed on the screen of a PC (personal computer) 27 via the sensor interface 26 .
図7は分力Fyの変動による溶接強度の関連を表すグラフである。強度の限界値Hは製品の用途や被溶接物の材質及び板厚により、強度の限界値Hを設定する。JISZ3140に記載してあるA級、B級、C級に溶接強度を分類しているのと同様である。また、グラフにおけるP値は溶接強度の限界値Hのときの分力Fyの値であり、これを閾値とする。この閾値よりもFyの数値が大きくなったときは、溶接異常と判定する。 FIG. 7 is a graph showing the relationship of the welding strength due to the fluctuation of the component force Fy. The strength limit value H is set according to the application of the product and the material and thickness of the workpiece. This is the same as classifying the welding strength into class A, class B and class C described in JISZ3140. Moreover, P value in a graph is the value of the component force Fy in case of the limit value H of welding strength, and makes this a threshold value. When the numerical value of Fy becomes larger than this threshold, it is determined that the welding is abnormal.
図8のグラフは溶接直後に分力の測定値FyがPC27画面に表示されたものである。リアルタイムで閾値との関連を判別でき、即座に異常を検出でき、不良品の流出を未然に防ぐことができる。(a)は本発明の2分力計使用時のものである。(b)は今後他の溶接機を使用しFx、Fyの計測が必要となった場合、3分力計を設置したときの参考の事例である。 In the graph of FIG. 8, the measured force Fy of the component force is displayed on the PC27 screen immediately after welding. The relationship with the threshold can be determined in real time, an abnormality can be detected immediately, and the outflow of defective products can be prevented. (A) is when the two-component force meter of the present invention is used. (B) is a reference example when a three-component force meter is installed when it is necessary to measure Fx and Fy using another welding machine in the future.
スポット溶接する金属板製品の異常な溶接を検出し、品質の良否を即座に判定し、不具合品の流出を、未然に防止できる。 Abnormal welding of spot-welded metal plate products can be detected, quality can be determined immediately, and outflow of defective products can be prevented.
1 スポット溶接機
2 躯体
3 上電極
4 下電極
6 加圧用エアシリンダ
7 上電極ホルダ
8 ツバ部
9 下電極ホルダ
11 溶接チップ
12 溶接トランス
13 導電板(オンス銅板)
20 3方向分力計
21 2方向分力計
22 八角弾性リング
23 歪ゲージ
24 異形孔
25 挿入孔
26 センサインターフェース
27 PC
30 支持体
H 溶接強度の限界値
P 閾値とした分力
W 被溶接材
1 Spot Welder 2 Housing 3 Upper Electrode 4 Lower Electrode 6 Pressurizing Air Cylinder
7 Upper electrode holder 8 Head 9 Lower electrode holder 11 Welding tip 12 Welding transformer 13 Conductive plate (ounce copper plate)
20 3-way force meter 21 2-way force meter 22 Octagonal elastic ring 23 Strain gauge 24 Deformed hole 25 Insert hole 26 Sensor interface 27 PC
30 Support H Limit value P of welding strength Component W W
Claims (2)
固定側の下電極にツバ部を設け、前記ツバ部の下面で押圧されるよう2分力計を設置し、
前記2分力計は八角弾性リングの横方向の6箇所の表面と複数の異形孔部に歪ゲージを取り付け、上面の加圧力を2分力Fz、Fyに分解し検知するよう構成し、
一方の分力Fyが、前もって定めた閾値を越えたときに、異常と警告するシステムを備えた、
スポット溶接機の溶接品質監視方法。 In spot welders,
Provide a brim portion on the lower electrode of the fixed side, and install a two-component force meter to be pressed by the lower surface of the brim portion,
The two-component force meter is configured to attach strain gauges to six lateral surfaces of the octagonal elastic ring and a plurality of deformed holes, and to disassemble and detect the applied pressure on the upper surface into two component forces Fz and Fy,
When one component force Fy exceeds a predetermined threshold value, a system is provided that warns that there is an abnormality.
Weld quality monitoring method for spot welders.
固定側の下電極にツバ部を設け、前記ツバ部の下面で押圧されるよう2分力計を設置し、
前記2分力計は八角弾性リングの横方向の6箇所の表面と複数の異形孔部に歪ゲージを取り付け、上面の加圧力を2分力Fz、Fyに分解し検知するよう構成し、
一方の分力Fyが、前もって定めた閾値を越えたときに、異常と警告するシステムを備えた、
スポット溶接機の溶接品質監視装置。 In spot welders,
Provide a brim portion on the lower electrode of the fixed side, and install a two-component force meter to be pressed by the lower surface of the brim portion,
The two-component force meter is configured to attach strain gauges to six lateral surfaces of the octagonal elastic ring and a plurality of deformed holes, and to disassemble and detect the applied pressure on the upper surface into two component forces Fz and Fy,
When one component force Fy exceeds a predetermined threshold value, a system is provided that warns that there is an abnormality.
Spot welding machine welding quality monitoring device.
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JP2000301349A (en) * | 1999-04-26 | 2000-10-31 | Matsushita Electric Ind Co Ltd | Device for inspecting resistance welding |
JP2007203320A (en) * | 2006-01-31 | 2007-08-16 | Koyo Giken:Kk | Spot welding equipment |
JPWO2010110316A1 (en) * | 2009-03-24 | 2012-10-04 | 有限会社中▲野▼製作所 | Electric pressure resistance welding machine |
JP5301369B2 (en) * | 2009-06-26 | 2013-09-25 | 本田技研工業株式会社 | Seam welding apparatus and seam welding method |
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