The present invention provides a weld monitoring system and method that monitors and automatically coordinates information on the quality of each weld in a workpiece having one or more welds. In particular, each weld in the workpiece is automatically analyzed at the time it is being made using weld sensors such as those that measure current, wire feed, voltage, and gas flow to produce information on the quality of the weld. Using this information, the welds are sorted, displayed, and logged with workpiece and weld number information which is provided to the operator in real-time and stored in a computer for access at a later time for quality control or other purposes. Therefore, the system and method enables welds of a quality less than a pre-determined quality for the weld to be identified in real-time and information concerning any particular weld to be accessed at a later time.

Method and system for weld monitoring and tracking

A welding training system includes one or more welding operator device which provides positional feedback relevant to a quality weld. The positional feedback is analyzed and, when the positional feedback is outside of a predetermined range, a signal is provided to the welding operator. In one embodiment, tactile feedback is provided in a welding gun.

Welding training system

Methods and apparatus are provided for monitoring resistance spot welding process conditions in real time by using welding data in an energy balance model in integral form to estimate the mean weld temperature and to predict process conditions such as occurrence of splash, and weld diameter. Using predicted welding process conditions, welding parameters are modified in real time to prevent splash and produce sound welds.

Spot welding system and method for sensing welding conditions in real time

A welding tool includes a first handle and a second handle. The welding tool also includes a torch nozzle holder configured to hold a nozzle of a welding torch therein, and to block the nozzle from extending therethrough. The welding tool includes a blade assembly positioned a predetermined distance from the torch nozzle holder. The blade assembly is configured to cut welding wire extending through the blade assembly to calibrate wire stickout from the welding torch to the predetermined distance.

Welding training systems and devices

A system and device for welding training. In one example, a welding training system includes a position detecting system configured to detect a distance between the position detecting system and objects within a field of view of the position detecting system, and to produce a map corresponding to the objects. The welding training system also includes a markers configured to be coupled to a device of the welding training system. Furthermore, the markers are configured to be detected by the position detecting system.

System and device for welding training

A welding voltage output from a power source of a resistance welder is derived on the basis of a welding current and an interelectrode voltage, and diameter of a nugget which is formed in a sheetlike work to be welded is estimated on the basis of the welding current, the welding voltage, data of material constant and a thickness of the sheetlike work, subsequently, the estimated diameter of nugget is composed with a target diameter of nugget, and thereby quality of the resistance welding is determined.

Resistance welding monitor

A method for evaluating quality of a resistance weld is provided, in which a nugget generation state during a welding process is evaluated by observable numerical values based on physical phenomena, and which can afford a wide application range in welding material as well as a capability of accurate knowledge as to the nugget generation state of the weld. Based on that a specific resistance value of a metal material to be welded has a temperature dependency in a conduction state of AC or current-pulsated welding current, a rate of change of inter-chip dynamic resistance instantaneous value during a current changing period is determined, a changing state of the dynamic resistance instantaneous value is further calculated, and a heat-generating state of a weld zone, i.e., a nugget formation state is estimated. Thus, a quality evaluation of a weld is performed accurately.

Method and apparatus for evaluating quality of resistance welds

An optical machining device with high reliability and stable connection quality, comprising a semiconductor laser (1) and an optical system (5) disposed in a machining gas flow passage, wherein machining gas has moisture-proofing and dust-proofing effects on the semiconductor laser (1) and the optical system (5), cools the semiconductor laser (1) and the optical system (5), flows to a lens holder (6) to increase the cooling effect on the optical system (5) so as to increase an optical accuracy, and also flows to the surface of a cover glass (7) inside a nozzle (8) for injecting the machining gas onto a work (11) to prevent the surface of the cover glass (7) from being damaged and contaminated, whereby the machining gas is injected on the sama axis as the output direction of light to increase the shielding capability of a machined part (12).

Optical machining device

A control apparatus for a resistance welding machine comprises a welding current detecting device (5; 205) for detecting a welding current, interelectrode voltage detecting device (6; 206) for detecting an interelectrode voltage, a calculating section (13; 213) for predicting a nugget growth or estimating an expulsion & surface-flash generation probability, and control section (16, 17, 18; 212, 215) for controlling the welding current so that the nugget growth or the expulsion & surface-flash generation probability can be adjusted to a predetermined value.

Control apparatus for resistance welding machine

The invention concerns a method of controlling welding conditions of a resistance welder, in which the nugget generating state can be estimated with general-purpose properties, and in which accurate and high-quality resultant welding can be obtained. Through a process including the steps of detecting a welding current and a chip-to-chip voltage, using a heat conduction simulator for performing simulation of a welding portion on the basis of heat conduction calculation from the detected welding current and the detected chip-to-chip voltage, estimating a status quantity expressing the state in which a nugget is formed in the welding portion during welding, and comparing the status quantity with a reference status quantity at the time of estimation, wherein correcting the welding conditions and modifying a configuration of the heat conduction simulator in such a way that a numerical value thereof is corrected on the basis of a monitored value expressing a state of welding after welding are performed on the basis of the result of comparison so as to make said status quantity coincide with said reference status quantity, it is possible to control the welding conditions accurately, and it is possible to obtain accurate and high- quality resultant welding.

Makoto Ryudo

Papers

Resistance welding monitor

Method and apparatus for evaluating quality of resistance welds

Optical machining device

Control apparatus for resistance welding machine

Method of controlling welding conditions of a resistance welder