Process for checking a laser weld seam

• US 7,620,233 B2
• Filed: 01/07/2005
• Issued: 11/17/2009
• Est. Priority Date: 01/07/2004
• Status: Expired due to Fees

• Current Assignee: Daimler AG (Mercedes-Benz Group AG)
• Original Assignee: Daimler AG (Mercedes-Benz Group AG)
• Inventors: Beck, Markus, Herzinger, Thomas
• Primary Examiner(s): Desire; Gregory M
• Application Number:
  US11/031,858
• Publication Number:
  US 20050163364A1
• Time in Patent Office: 1,775 Days
• Field of Search: 219/121.6, 219/121.63, 219/121.64, 219/121.76, 219/121.83, 219/121.82, 219/121.13, 219/121.61, 219/121.78, 250/559.01, 250/559.05, 250/559.29, 382/143, 382/152, 382/141, 382/149, 700/166
• US Class Current: 382/152
• CPC Class Codes: B23K 26/032 using optical means
• CPC Class Codes: G01N 21/4738 Diffuse reflection precedence is given to G01N21/55 - G01N21/57 if specular component is taken into consideration, e.g. also for testing fluids, fibrous materials
• CPC Class Codes: G06T 2207/30152 Solder
• CPC Class Codes: G06T 7/0004 Industrial image inspection

Abstract

When laser beam welding one or more work pieces faults may occur, which lead to unacceptable losses in quality. A check process is provided, which reliably recognizes seam faults in a seam which is introduced into one or more workpieces by means of laser beam welding. Characteristic signals are detected from the region of the seam using a sensor and compared with an index value or set value, and only signals are taken into consideration which are detected in a characteristic time interval following the laser beam welding, which begins, at the earliest, following the solidification of the seam.

Claims

1. A process for checking a laser weld seam, comprising:

selecting materials to be welded and the process parameters of the laser welding process for forming a weld seam,

determining the time after welding at which at least a thin skin has solidified on the weld seam and setting this as the earliest measurement start time for a characteristic interval,

selecting an optical or thermal signal to be emitted onto and reflected from the weld seam during said characteristic interval,

determining the minimal length of a time interval necessary in order to receive detectable signal data, and setting this as the minimal duration of the characteristic time interval,

laser welding said materials to form a weld seam by a computer controlled process comprising;

emitting said optical or thermal signal onto said seam in said area in which at least a thin skin has solidified and detecting reflected signal data,

comparing the detected reflected signal data with desired values,

providing a violation signal each time the detected reflected signal data does not correspond with the desired values, and

evaluating the laser weld seam on the basis of said violation signals,

wherein only signals detected within the characteristic time interval are taken into consideration.

2. The process according to claim 1, wherein the characteristic time interval is defined depending upon the material characteristics of the workpiece and the process parameters of the laser beam.

3. The process according to claim 1, wherein detected signals of the optical and/or thermal type are emitted or reflected out from the area of the seam.

4. The process according to claim 1, wherein the signals are detected using a CCD-camera or a CMOS-camera.

5. The process according to claim 1, wherein the measurement signal is produced by redirecting the welding laser back onto the already welded seam with sufficient energy to produce a reflected signal but without causing the seam to remelt, and is directed in the direction of and onto the seam via suitable beam deflection mechanisms.

6. The process according to claim 5, wherein the measurement signal is produced by the welding laser and is directed in the direction of and onto the seam via a scanner device.

7. The process according to claim 1, further comprising placing a beam splitter in the beam path of the laser beam, such that the beam splitter directs the measurement signal to the weld seam in said area in which the weld seam has solidified, and such that the reflection of the laser from the area in which the weld seam has solidified is directed to the sensor.

8. The process according to claim 7, further comprising placing a shutter in the beam path of the laser beam, wherein said shutter is provided between beam splitter and sensor and closes this path during welding, in order to protect the sensor from too strong a signal.

9. The process according to claim 1, wherein the earliest measurement start time for the characteristic interval is the time at which the weld seam completely solidifies.

10. The process according to claim 1, wherein the two-fold of the minimal necessary measurement duration in order to receive detectable signal data is set as the minimal duration of the characteristic time interval.

11. The process according to claim 1, wherein said material is metal.

12. The process according to claim 11, wherein said metal is in the form of sheet metal.

13. A process for checking a laser weld seam, comprising:

selecting materials to be welded and the process parameters of the laser welding process for forming a weld seam,

determining the time after welding at which said weld seam has solidified and setting this as the earliest measurement start time for a characteristic interval,

selecting a speed or power at which said laser when redirected onto said solidified weld seam does not cause said weld seam to remelt,

determining the minimal length of a time interval necessary in order to receive a detectable signal data from the reflection of said redirected laser beam, and setting the two-fold of this as the minimal duration of the characteristic time interval,

laser welding said materials to form a weld seam by a computer controlled process comprising;

redirecting said laser beam onto said seam in said area in which said weld seam has solidified and detecting reflected signal data,

comparing the detected reflected signal data with desired values,

providing a violation signal each time the detected reflected signal data does not correspond with the desired values, and

evaluating the laser weld seam on the basis of said violation signals,

wherein only signals detected within the characteristic time interval are taken into consideration.

14. A computer controlled process for checking a laser weld seam, wherein said computer directs process steps comprising:

guiding a laser to form a first step-weld with a laser beam,

guiding the laser to form a second step weld with said laser beam,

steering said laser beam back to said first step weld after said first step weld has solidified, wherein the laser beam is guided onto the first step weld with insufficient energy input to melt said first step-weld, and detecting the reflected signal data,

comparing the detected reflected signal data with desired values,

generating and recording in memory a violation signal each time the detected reflected signal data does not correspond with the desired values, and

evaluating the quality of the laser weld seam on the basis of said violation signals.

15. A process for checking a laser weld seam, comprising:

selecting materials to be welded and the process parameters of the laser welding process for forming a weld seam,

determining the time after welding at which at least a thin skin has solidified on the weld seam and setting this as the earliest measurement start time for a characteristic interval,

determining the minimal length of a time interval necessary in order to receive detectable signal data, and setting this as the minimal duration of the characteristic time interval,

laser welding said materials to form a weld seam by a computer controlled process comprising;

receiving signals of optical and/or thermal type which are emitted out of the area of the seam in which at least a thin skin has solidified however the seam is still glowing,

comparing the detected signal data with desired values,

providing a violation signal each time the detected reflected signal data does not correspond with the desired values, and

evaluating the laser weld seam on the basis of said violation signals,

wherein only signals detected within the characteristic time interval are taken into consideration.

16. The process as in claim 15, wherein said signals are of the optical type.

17. The process as in claim 15, wherein said signals are of the thermal type.