Method and apparatus for monitoring weld quality
First Claim
1. A method for monitoring quality of a weld bead during a welding process utilizing an electronic controller, comprising the steps of:
- determining an average power spectral density value for a first welding parameter signal between a first predetermined frequency and a second predetermined frequency;
determining an average power spectral density value for a second welding parameter signal between a first predetermined frequency and a second predetermined frequency; and
comparing said average power spectral density value for said second welding parameter signal with said average power spectral density value for said first welding parameter signal and terminating said welding process if said average power spectral density value for said first welding parameter signal exceeds said average power spectral density value for said second welding parameter signal.
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Accused Products
Abstract
A method and apparatus for monitoring quality of a weld bead during a welding process utilizing an electronic controller is disclosed. The method and apparatus includes determining an average power spectral density value for a first welding parameter signal between a first predetermined frequency and a second predetermined frequency, determining an average power spectral density value for a second welding parameter signal between a first predetermined frequency and a second predetermined frequency, and comparing the average power spectral density value for the second welding parameter signal with the average power spectral density value for the first welding parameter signal and terminating the welding process if the average power spectral density value for the first welding parameter signal exceeds the average power spectral density value for the second welding parameter signal.
25 Citations
32 Claims
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1. A method for monitoring quality of a weld bead during a welding process utilizing an electronic controller, comprising the steps of:
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determining an average power spectral density value for a first welding parameter signal between a first predetermined frequency and a second predetermined frequency;
determining an average power spectral density value for a second welding parameter signal between a first predetermined frequency and a second predetermined frequency; and
comparing said average power spectral density value for said second welding parameter signal with said average power spectral density value for said first welding parameter signal and terminating said welding process if said average power spectral density value for said first welding parameter signal exceeds said average power spectral density value for said second welding parameter signal. - View Dependent Claims (2)
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3. A method for monitoring quality of a weld bead during a welding process utilizing an electronic controller, comprising the steps of:
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determining an average area under a first welding parameter signal between a first predetermined frequency and a second predetermined frequency;
determining a combination average area limit value for both a second welding parameter signal and a third welding parameter signal; and
comparing said combination average area limit value for both said second welding parameter signal and said third welding parameter signal with said average area under said first welding parameter signal and terminating said welding process if said average area under said first welding parameter signal exceeds said combination average area limit value for both said second welding parameter and said third welding parameter signal. - View Dependent Claims (4, 5, 6, 7, 8, 9, 10, 11)
determining an average value for the second welding parameter and an average value for the third welding parameter; and
comparing said average value for the second welding parameter and said average value for the third welding parameter with preestablished average area limit values and determining a combination average area limit value.
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8. The method, as set forth in claim 7, wherein said step of determining a combination average area limit value further includes utilizing bilinear interpolation on said preestablished average area limit values.
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9. The method, as set forth in claim 7, wherein said step of determining a combination average area limit value further includes utilizing nonlinear regression on said preestablished average area limit values.
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10. The method, as set forth in claim 7, wherein said preestablished average area limit values are located in an array.
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11. The method, as set forth in claim 7, wherein said preestablished average area limit values are developed from empirical data.
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12. A method for monitoring quality of a weld bead during a welding process utilizing an electronic controller, comprising the steps of:
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determining an average area under a first welding parameter signal between a first predetermined frequency and a second predetermined frequency during a first predetermined time interval that is updated every second predetermined time interval;
determining a combination average area limit value for both a second welding parameter signal and a third welding parameter signal during a third predetermined time interval that is updated every fourth predetermined time interval; and
comparing said combination average area limit value for both said second welding parameter signal and said third welding parameter signal with said average area under said first welding parameter signal and terminating said welding process if said average area under said first welding parameter signal exceeds said combination average area limit value for both said second welding parameter signal and said third welding parameter signal for a fifth predetermined time interval that is updated every sixth predetermined time interval. - View Dependent Claims (13)
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14. A method for monitoring quality of a weld bead during a welding process utilizing an electronic controller, comprising the steps of:
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determining an average power spectral density value for a current signal between a first predetermined frequency and a second predetermined frequency during a first predetermined time interval that is updated every second predetermined time interval and determining an average value for a voltage signal and an average value for a wire feed speed signal during a third predetermined time interval that is updated every fourth predetermined time interval;
determining an average area limit value by comparing said average value for a voltage signal and said average value for a wire feed speed signal with average area limit values located in a preestablished array by utilizing bilinear interpolation; and
comparing said average power spectral density value for said first welding parameter signal with said average area limit value and terminating said welding process if said average power spectral density value of said current signal exceeds said average area limit value for a fifth predetermined time interval that is updated every sixth predetermined time interval.
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15. A method for monitoring quality of a weld bead during a welding process utilizing an electronic controller, comprising the steps of:
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determining an average power spectral density value for a current signal between a first predetermined frequency and a second predetermined frequency during a first predetermined time interval that is updated every second predetermined time interval and determining an average value for a voltage signal and an average value for a wire feed speed signal during a third predetermined time interval that is updated every fourth predetermined time interval;
determining an average area limit value by comparing said average value for a voltage signal and said average value for a wire feed speed signal with average area limit values located in a preestablished array by utilizing nonlinear regression; and
comparing said average power spectral density value for said first welding parameter signal with said average area limit value and terminating said welding process if said average power spectral density value of said current signal exceeds said average area limit value for a fifth predetermined time interval that is updated every sixth predetermined time interval.
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16. A method for monitoring quality of a weld bead during a welding process utilizing an electronic controller, comprising the steps of:
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determining an average power spectral density value for a current signal between a first predetermined frequency and a second predetermined frequency during a first predetermined time interval that is updated every second predetermined time interval and determining an average value for a voltage signal and an average value for a wire feed speed signal during a third predetermined time interval that is updated every fourth predetermined time interval;
determining an average area limit value by comparing said average value for a voltage signal and an average value for a wire feed speed signal with average area limit values located in a preestablished array by utilizing bilinear interpolation;
comparing said average power spectral density value for said first welding parameter signal with said average area limit value and setting an indicator equal to one if said average power spectral density value of said current signal exceeds said average area limit value and setting an indicator to zero if said average limit value exceeds said average power spectral density value of said current signal for a fifth predetermined time interval that is updated every sixth predetermined time interval;
summing a value of said indicators for a seventh predetermined time interval that is updated every eighth predetermined time interval; and
terminating said welding process if said summation of said indicators exceeds a predetermined maximum value.
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17. An apparatus for monitoring quality of a weld bead during a welding process comprising:
an electronic controller for receiving a first welding parameter signal and a second welding parameter signal and then determining an average power spectral density value for said first welding parameter signal between a first predetermined frequency and a second predetermined frequency and determining an average power spectral density value for said second welding parameter signal area between a first predetermined frequency and a second predetermined frequency and then comparing said average power spectral density value for said second welding parameter signal with said average power spectral density value for said first welding parameter signal and terminating said welding process if said average power spectral density value for said first welding parameter signal exceeds said average power spectral density value for said second welding parameter signal. - View Dependent Claims (18)
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19. An apparatus for monitoring quality of a weld bead during a welding process comprising:
an electronic controller for receiving a first welding parameter signal, a second welding parameter signal, and a third welding parameter signal and then determining an average area under a first welding parameter signal between a first predetermined frequency and a second predetermined frequency and determining a combination average area limit for both a second welding parameter signal and a third welding parameter signal and then comparing said combination average area limit for both said second welding parameter signal and said third welding parameter signal with said average area under said first welding parameter signal and terminating said welding process if said average area under said first welding parameter signal exceeds said combination average area limit for both said second welding parameter signal and said third welding parameter signal. - View Dependent Claims (20, 21, 22, 23, 24, 25, 26, 27)
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28. An apparatus for monitoring quality of a weld bead during a welding process comprising:
an electronic controller for receiving a first welding parameter signal, a second welding parameter signal, and a third welding parameter signal and then determining an average area under a first welding parameter signal between a first predetermined frequency and a second predetermined frequency during a first predetermined time interval that is updated every second predetermined time interval and determining a combination average area limit value for both a second welding parameter signal and a third welding parameter signal during a third predetermined time interval that is updated every fourth predetermined time interval and then comparing said combination average area limit value for both said second welding parameter signal and said third welding parameter signal with said average area under said first welding parameter signal and terminating said welding process if said average area under said first welding parameter signal exceeds said combination average area limit value for both said second welding parameter signal and said third welding parameter signal for a fifth predetermined time interval that is updated every sixth predetermined time interval. - View Dependent Claims (29)
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30. An apparatus, for monitoring quality of a weld bead during a welding process, comprising:
an electronic controller for receiving a current signal, a voltage signal and a wire feed speed signal and then determining an average power spectral density value for a current signal between a first predetermined frequency and a second predetermined frequency during a first predetermined time interval that is updated every second predetermined time interval and determining an average value for a voltage signal and an average value for a wire feed speed signal during a third predetermined time interval that is updated every fourth predetermined time interval and determining an average area limit value by comparing said average value for a voltage signal and said average value for a wire feed speed signal with average area limit values located in a preestablished array by utilizing bilinear interpolation and then comparing said average power spectral density value for said first welding parameter signal with said average area limit value and terminating said welding process if said average power spectral density value of said current signal exceeds said average area limit value for a fifth predetermined time interval that is updated every sixth predetermined time interval.
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31. An apparatus, for monitoring quality of a weld bead during a welding process, comprising:
an electronic controller for receiving a current signal, a voltage signal and a wire feed speed signal and then determining an average power spectral density value for a current signal between a first predetermined frequency and a second predetermined frequency during a first predetermined time interval that is updated every second predetermined time interval and determining an average value for a voltage signal and an average value for a wire feed speed signal during a third predetermined time interval that is updated every fourth predetermined time interval and determining an average area limit value by comparing said average value for a voltage signal and said average value for a wire feed speed signal with average area limit values located in a preestablished array by utilizing nonlinear regression and then comparing said average power spectral density value for said first welding parameter signal with said average area limit value and terminating said welding process if said average power spectral density value of said current signal exceeds said average area limit value for a fifth predetermined time interval that is updated every sixth predetermined time interval.
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32. An apparatus, for monitoring quality of a weld bead during a welding process, comprising:
an electronic controller for receiving a current signal, a voltage signal and a wire feed speed signal and then determining an average power spectral density value for a current signal between a first predetermined frequency and a second predetermined frequency during a first predetermined time interval that is updated every second predetermined time interval and determining an average value for a voltage signal and an average value for a wire feed speed signal during a third predetermined time interval that is updated every fourth predetermined time interval and determining an average area limit value by comparing said average value for a voltage signal and an average value for a wire feed speed signal with average area limit values located in a preestablished array by utilizing bilinear interpolation and then comparing said average power spectral density value for said first welding parameter signal with said average area limit value and setting an indicator equal to one if said average power spectral density value of said current signal exceeds said average area limit value and setting an indicator to zero if said average limit value exceeds said average power spectral density value of said current signal for a fifth predetermined time interval that is updated every sixth predetermined time interval and then summing a value of said indicators for a seventh predetermined time interval that is updated every eighth predetermined time interval and then terminating said welding process if said summation of said indicators exceeds a predetermined maximum value.
Specification