METHOD AND SYSTEM FOR WELD PROCESS MONITORING

• US 20040112874A1
• Filed: 12/11/2002
• Published: 06/17/2004
• Est. Priority Date: 12/11/2002
• Status: Active Grant

• Current Assignee: Ent Services Development Corporation LP (DXC Technology Company)
• Original Assignee: Electronic Data Systems Corporation (Perspecta, Inc.)
• Inventors: Nastasi, John D. Jr.
• Granted Patent: US 6,750,418 B1
• Time in Patent Office: Days
• US Class Current: 219/109
• CPC Class Codes: B23K 11/252 using digital means
• CPC Class Codes: B23K 11/3063 Electrode maintenance, e.g. cleaning, grinding

Abstract

A weld tip testing element is presented. The weld tip testing element includes a first alignment member and a first lever element coupled to the alignment member. The first lever element is further coupled to a first pivot and the first alignment member is operable to determine a first alignment associated with a weld tip. If the weld tip is out of alignment the weld tip contacts the first alignment member.

Claims

1. A weld tip testing element comprising:

a first alignment member;

a first lever element coupled to the alignment member;

the first lever element being further coupled to a first pivot; and

wherein the first alignment member is operable to determine a first alignment associated with a weld tip, wherein if the weld tip is out of alignment the weld tip contacts the first alignment member.

2. The weld tip testing element according to claim 1, wherein the first alignment member further comprises a aperture disposed therethrough, wherein the aperture is operable to removeably receive the weld tip.

3. The weld tip testing element according to claim 2, wherein a size of the aperture is based on an alignment tolerance associated with the weld tip and wherein the first alignment member and the first lever element are enclosed in a housing.

4. The weld tip testing element according to claim 1 and further comprising:

a mounting coupled to the first pivot and operable to support the first pivot, the first lever element and the first alignment member; and

a first sensor coupled to the mounting and operable to detect movement of the first lever element.

5. The weld tip testing element according to claim 4, wherein the first sensor is further operable to detect misalignment of the weld tip based on contact between the first sensor and the first lever element.

6. The weld tip testing element according to claim 5 and further comprising:

a second alignment member coupled to the mounting, the second alignment member operable to detect a second alignment associated with the weld tip;

a second lever element coupled to the second alignment member and coupled to the mounting;

wherein the first and second alignment members form an aperture operable to removably receive the weld tip; and

wherein if the weld tip is out of alignment, at least one of the first and second lever elements moves in response to contact between the weld tip and at least one of the first and second alignment members.

7. The weld tip testing element according to claim 1 and further comprising:

computer software encoded on storage and operable to;

receive first alignment information from the first sensor;

analyze the first alignment information with respect to at least one expected alignment value;

generate an alarm based on the analysis; and

generate a fault based on the analysis.

8. The weld tip testing element according to claim 7, wherein the computer software is further operable to:

generate the alarm when the first alignment is outside a range of expected alignments, the expected alignments indicating proper values for the first alignment; and

generating the fault when the alarm is within a range of fault alignments, the fault alignments indicating values associated serious mis-alignment of the weld tip.

9. The weld tip testing element according to claim 1, wherein the weld tip comprises a pair of weld tips and further comprising:

a pressure sensor operable to determine a squeeze force associated with the weld tips, the pressure sensor coupled to the mounting; and

a heat sensor operable to determine a temperature associated with the weld tip, the heat sensor coupled to the mounting.

10. The weld tip testing element according to claim 1, wherein the first alignment member comprises a generally flat bar with at least one generally rounded end and having an aperture disposed therethrough.

11. The weld tip testing element according to claim 1, wherein the first alignment member operates to depress in response to contact with the weld tip and wherein the first lever element causes generation of a piezo-electric charge in response to contact with the first sensor.

12. The weld tip testing element according to claim 1, wherein the alignment member comprises a generally circular element.

13. A weld process monitor comprising:

a pressure sensor operable to determine a squeeze force associated with a weld tip, the pressure sensor coupled to a mounting;

a heat sensor operable to determine a temperature associated with the weld tip, the heat sensor coupled to the mounting;

a pivot coupled to the mounting;

an alignment member having an aperture disposed therein and coupled to a lever element, the lever element being further coupled to the pivot, wherein the aperture is operable to removably receive the weld tip;

an alignment sensor operable to detect movement of the lever element and determine an alignment associated with the weld tip; and

computer software encoded on storage and operable to;

analyze at least one of the squeeze force, the temperature and the alignment with respect to at least one expected value;

generate an alarm based on the analysis; and

generate a fault based on the analysis.

14. The weld process monitor according to claim 13, wherein the alignment member comprises a generally flat bar with a generally rounded end and having the aperture disposed therethrough.

15. The weld process monitor according to claim 13, wherein the software is further operable to:

compare one of the squeeze force, the temperature or the alignment to one of a respective range of expected squeeze forces, a range of expected temperatures or a range of expected alignments;

generate the alarm when one of the squeeze force, the temperature or the alignment exceeds one of the range of respective expected squeeze forces, expected temperatures or expected alignments, the alarm including one of the squeeze force, the temperature or the alignment and one of the range of expected squeeze forces, expected temperatures or expected alignments; and

communicate the alarm to an appropriate recipient.

16. The weld process monitor according to claim 13, wherein the software is further operable to:

compare one of the squeeze force, the temperature or the alignment to one of a range of fault squeeze forces, a range of fault temperatures or a range of fault alignments;

generate the fault when one of the squeeze force, the temperature or the alignment is respectively within one the range of fault squeeze forces, the range of fault temperatures or the range of fault alignments, the fault including at least one of the squeeze force, the temperature and the alignment and at least one of the range of fault squeeze forces, the range of fault temperatures and the range of fault alignments; and

communicate the fault to an appropriate recipient.

17. The weld process monitor according to claim 13, wherein the alignment sensor is operable to determine the alignment of the weld tip in response to the weld tip touching the alignment member moving the lever element about the pivot to contact the alignment sensor.

18. The weld process monitor according to claim 17, wherein the alignment member further operates to depress in response to contact with the weld tip and wherein the alignment sensor causes generation of a piezo-electric charge in response to contact between the lever element and the alignment sensor.

19. The weld process monitor according to claim 13, wherein the alignment member comprises a generally circular element and a size of the aperture is based on an alignment tolerance associated with the weld tip.

20. The weld process monitor according to claim 13,

wherein the alignment member is generally circular;

wherein the lever portion comprises a rod;

wherein the aperture is generally circular;

wherein the pressure sensor comprises one of a strain gauge or a mechanical sensor; and

wherein the heat sensor comprises one of an infrared sensor or a thermocouple.