WELD DEFECT DETECTION SYSTEMS AND METHODS FOR LASER HYBRID WELDING

• US 20100314362A1
• Filed: 05/07/2010
• Published: 12/16/2010
• Est. Priority Date: 06/11/2009
• Status: Active Grant

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Illinois Tool Works Inc.
• Inventors: Albrecht, Bruce Patrick
• Granted Patent: US 8,552,337 B2
• Time in Patent Office: Days
• US Class Current: 219/121.63
• CPC Class Codes: B23K 26/032 using optical means
• CPC Class Codes: B23K 26/20 Bonding soldering by means of radiant energy B23K1/005; joining of preformed plastics parts by heating using laser beam B29C65/16
• CPC Class Codes: B23K 26/348 in combination with arc heating, e.g. TIG [tungsten inert gas], MIG [metal inert gas] or plasma welding laser beam for starting a welding or cutting arc B23K9/067
• CPC Class Codes: B23K 28/02 Combined welding or cutting procedures or apparatus
• CPC Class Codes: B23K 31/12 relating to investigating the properties, e.g. the weldability, of materials
• CPC Class Codes: B23K 31/125 Weld quality monitoring
• CPC Class Codes: B23K 37/00 Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups eye-shields for welders worn on the operator's body or carried in the hand A61F9/00 , i.e. A61F9/02; applicable to metal-working machines other than soldering, welding, or flame-cutting machines B23Q; laser protective screens B23K26/706; protective shields for other welding methods F16P1/06
• CPC Class Codes: B23K 9/0953 using computing means
• CPC Class Codes: B23K 9/0956 using sensing means, e.g. optical

Abstract

Laser hybrid welding systems adapted to identify and/or fix a weld defect occurring during a laser hybrid welding process are provided. Embodiments of the laser hybrid welding system may include one or more devices that provide feedback to a controller regarding one or more weld parameters. One embodiment of the laser hybrid welding system includes sensors that are adapted to measure the weld voltage and/or amperage during the welding process and transmit the acquired data to the controller for processing. Another embodiment of the laser hybrid welding system includes a lead camera and a lag camera that film an area directly in front of the weld location and directly behind the weld location.

Claims

1. A laser hybrid welding system, comprising:

a welder configured to perform a laser hybrid welding operation in which a workpiece is heated by a laser and filler metal is added by an arc welding process;

a sensor configured to acquire data regarding a parameter of the laser hybrid welding operation; and

a controller communicatively coupled to the sensor and configured to receive the acquired data from the sensor, to determine whether the acquired data is indicative of a welding defect, and if the acquired data is indicative of a welding defect, to output a control signal that directs the laser hybrid welding system to attempt to fix the welding defect.

2. The laser hybrid welding system of claim 1, wherein the sensor comprises at least one of a voltage sensor, a current sensor, an audio sensor, a leading camera, and a following camera.

3. The laser hybrid welding system of claim 1, further comprising an operator interface that is configured to receive inputs from an operator regarding the welding operation and to convey information to the operator regarding a status of the welding operation.

4. The laser hybrid welding system of claim 3, wherein if the acquired data is indicative of the welding defect, the controller is further configured to notify the operator that an error has occurred.

5. The laser hybrid welding system of claim 1, wherein if the acquired data is indicative of the welding defect, the controller is further configured to record the welding defect event as an error, and to time and/or location stamp the recorded welding defect event.

6. The laser hybrid welding system of claim 1, wherein if the acquired data is indicative of the welding defect, the controller is further configured to utilize a clock signal to compute a location of the defect with respect to a reference location.

7. The laser hybrid welding system of claim 1, wherein the weld defect comprises at least one of a burn-through, a suck-back, an excess weld reinforcement, an inadequate weld reinforcement, improper alignment, a crack, an incomplete penetration, an incomplete fusion, and an undercut.

8. The laser hybrid welding system of claim 1, further comprising at least one of an encoder and a wireless signal configured to encode a defect location.

9. A controller for a laser hybrid welding system, comprising:

interface circuitry configured to receive data regarding a parameter of a laser hybrid welding operation and to output one or more control signals;

a processor communicatively coupled to the interface circuitry and configured to receive the data from the interface circuitry and to process the received data to determine if a weld defect has occurred; and

memory coupled to the processor and configured to receive and store the processed data from the processor for later retrieval.

10. The controller of claim 9, wherein if the processor determines that a weld defect has occurred, the processor is further configured to transmit a control signal to the interface circuitry that encodes instructions for the repair of the weld defect.

11. The controller of claim 10, wherein the interface circuitry is configured to receive and process the control signal from the processor and to output the one or more control signals that guide the operation of the components of the laser hybrid welding system to fix the weld defect.

12. The controller of claim 11, wherein if the weld defect is a burn-through with a size exceeding a preset threshold, the interface circuitry outputs a control signal that directs the laser to turn off and the arc welder to remain on to fix the burn through.

13. The controller of claim 12, wherein the control signal is configured to alternate between control of a laser parameter and control of a weld parameter to fix the burn through.

14. The controller of claim 11, wherein if the weld defect exceeds a preset length, the interface circuitry outputs, in the stated order, a control signal that directs a laser and an arc welder to turn off, a control signal that directs a torch positioner to a starting location of the weld defect, a control signal that directs the laser and the arc welder to turn on, and a control signal that directs the torch positioner to run another pass over the location of the weld defect.

15. The controller of claim 9, wherein if a weld defect has occurred, the processor is further configured to time stamp the weld defect and compute a location of the weld defect with respect to a reference location.

16. A laser hybrid welding system, comprising:

a welder configured to perform a laser hybrid welding operation in which a workpiece is heated by a laser and filler metal is added by an arc welding process;

a sensor configured to acquire data regarding a parameter of the laser hybrid welding operation; and

a controller communicatively coupled to the sensor and configured to receive the acquired data from the sensor, to determine whether the acquired data is indicative of a welding defect, and if the acquired data is indicative of a welding defect, to log the welding defect as an error in an associated memory.

17. The laser hybrid welding system of claim 16, wherein if the acquired data is indicative of the welding defect, the controller is further configured to utilize a clock signal to compute a location of the defect with respect to a reference location

18. The laser hybrid welding system of claim 16, wherein if the acquired data is indicative of the welding defect, the controller is further configured to direct the laser hybrid welding system to attempt to fix the welding defect.

19. The laser hybrid welding system of claim 16, wherein the sensor comprises a leading camera configured to record a first image of a pre-weld area and a following camera configured to record a second image of a post-weld area.

20. The laser hybrid welding system of claim 19, wherein the controller is configured to determine whether the acquired data is indicative of a welding defect by comparing the first image and the second image.