Method and system for weld process monitoring

• US 6,750,418 B1
• Filed: 12/11/2002
• Issued: 06/15/2004
• Est. Priority Date: 12/11/2002
• Status: Expired due to Term

• Current Assignee: Ent Services Development Corporation LP (DXC Technology Company)
• Original Assignee: Electronic Data Systems Corporation (Perspecta, Inc.)
• Inventors: Nastasi, John D. Jr.
• Primary Examiner(s): Shaw, Clifford C.
• Application Number:
  US10/316,971
• Publication Number:
  US 20040112874A1
• Time in Patent Office: 552 Days
• Field of Search: 219/109, 219/110, 219/86.41, 219/86.25
• 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 apparatus for use with a welder comprising a first weld tip and a second weld tip, the testing apparatus comprising:

a first alignment member coupled to a first pivot;

a first alignment sensor;

a second alignment member coupled to a second pivot;

a second alignment sensor different from the first alignment sensor;

wherein the first weld tip'"'"'s contacting of the first alignment member causes it to move;

wherein the first alignment sensor detects movement by the first alignment member;

wherein the second weld tip'"'"'s contacting of the second alignment member causes it to move; and

wherein the second alignment sensor detects movement by the second alignment member.

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

3. The weld tip testing apparatus according to claim 2, wherein a size of the aperture is based on an alignment tolerance associated with the first weld tip.

4. The weld tip testing apparatus according to claim 1 wherein the first alignment sensor detects movement by the first alignment member by detecting contact between the first alignment sensor and the first alignment member.

5. The weld tip testing apparatus according to claim 4, wherein the first alignment sensor comprises a piezo-electric sensor.

6. The weld tip testing apparatus according to claim 1, wherein the first alignment sensor comprises a laser.

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

computer software encoded on storage and operable to;

receive a signal from the first alignment sensor;

analyze the signal; and

generate an alarm based on the analysis.

8. The weld tip testing apparatus according to claim 1, wherein the first alignment sensor comprises a sensor selected from the group consisting of a magnetic sensor, a mechanical sensor, and an optical sensor.

9. The weld tip testing apparatus according to claim 1, and further comprising:

a pressure sensor operable to determine a squeeze force associated with at least the first weld tip; and

a heat sensor operable to determine a temperature associated with at least the first weld tip.

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

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

12. The weld tip testing apparatus according to claim 1, wherein the alignment member comprises multiple pieces joined together.

13. A weld process monitor for use with a welder comprising a first weld tip and a second weld tip, the weld process monitor comprising:

a pressure sensor operable to determine a squeeze force associated with at least the first weld tip;

a heat sensor operable to determine a temperature associated with at least the first weld tip;

a first alignment member coupled to a first pivot;

a first alignment sensor;

a second alignment member coupled to a second pivot;

a second alignment sensor different from the first alignment sensor;

wherein the first weld tip'"'"'s contacting of the first alignment member causes it to move;

wherein the first alignment sensor detects movement by the first alignment member;

wherein the second weld tip'"'"'s contacting of the second alignment member causes it to move; and

wherein the second alignment sensor detects movement by the second alignment member;

computer software encoded on storage and operable to;

analyze at least one of the squeeze force, the temperature, the detection of movement by the first sensor, and the detection of movement by the second sensor with respect to at least one expected value; and

generate an alarm based on the analysis.

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

15. The weld process monitor according to claim 14, wherein a size of the aperture is based on an alignment tolerance associated with the first weld tip.

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

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

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

communicate the alarm to an appropriate recipient.

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

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

generate a fault when one of the squeeze force or the temperature is respectively within one of the range of fault squeeze forces or the range of fault temperatures; and

communicate the fault to an appropriate recipient.

18. The weld process monitor according to claim 13, wherein the first alignment sensor detects movement by the first alignment member by detecting contact between the first alignment sensor and the first alignment member.

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

20. The weld process monitor according to claim 13, wherein the alignment member comprises multiple pieces joined together.

21. A method of testing a welder comprising a first weld tip and a second weld tip, the method comprising:

detecting motion of a first alignment member coupled to a first pivot using a first alignment sensor when the first weld tip contacts the first alignment member and causes it to move; and

detecting motion of a second alignment member coupled to a second pivot using a second alignment sensor separate from the first alignment sensor when the second weld tip contacts the first alignment member and causes it to move.

22. The method of claim 21, further comprising:

determining a squeeze force associated with at least the first weld tip using a pressure sensor.

23. The method of claim 22, further comprising:

determining a temperature associated with at least the first weld tip using a heat sensor.

24. The method of claim 23, further comprising:

using computer software to compare one of the squeeze force or the temperature to one of a range of fault squeeze forces or a range of fault temperatures;

generate a fault when one of the squeeze force or the temperature is respectively within one of the range of fault squeeze forces or the range of fault temperatures; and

communicate the fault to an appropriate recipient.

25. The method of claim 23, further comprising:

using computer software to compare one of the squeeze force or the temperature to one of a range of alarm squeeze forces or a range of alarm temperatures;

generate an alarm when one of the squeeze force or the temperature is respectively within one of the range of alarm squeeze forces or the range of alarm temperatures; and

communicate the alarm to an appropriate recipient.

26. The method of claim 21, wherein the first alignment sensor detects movement by the first alignment member by detecting contact between the first alignment sensor and the first alignment member.