Systems, methods, and apparatuses, of an arc welding (AW) process and quality monitoring

A method for monitoring a weld operation, comprising:

• configuring a weld system by a first stage of a scanning device for scanning a workpiece comprising a set of weld parts to generate a three-dimensional (3D) profile of a weld target wherein the 3D profile captures matching imperfections caused by a meeting of the set of weld parts when performing the weld operation for joining of the set of weld parts;
• configuring of the weld system by a second stage of a monitoring device for monitoring the weld operation and for generating high-resolution data of measurements of the weld operation;
• configuring the monitoring device by the first stage for determining a weld schedule based on the 3D profile of the weld target, and for adjusting the weld schedule while the weld operation is in progress for adapting to a predicted distortion in a shape of the weld based on the 3D profile of the target weld, and for adapting to sensed distortion during the weld operation resulting from a combination of forces caused by a weld between the set of weld parts and a clamping force exerted on the workpiece;
• configuring a plurality of sensors in the second stage for sensing a set of components associated with the weld operation for generating high-resolution data of measurements from direct and indirect sensing of measurements of the set of components associated with the weld operation in contrast to a low-resolution data of measurements provided by a weld controller, at least one or more of the plurality of sensors to provide indirect measurements of the weld operation comprising a microphone, a strain gauge sensor, and a welding reaction force sensor;
• configuring the microphone for monitoring ultrasonic frequencies and audible range frequencies of noises associated with the weld operation for determining whether the weld segment is compliant;
• configuring the strain gauge sensor for measuring a set of measurements exhibited by the weld part during the weld operation for determining a warping of the weld part and whether the warping of the weld part is beyond a compliant level wherein the strain gauge sensor is attached to the weld part;
• configuring the welding reaction force sensor for determining a strength of the weld segment in contrast to the clamping force applied to the weld part;
• configuring a weld system by a third stage of a processing monitoring module for qualifying the weld segment formed by the weld operation based on a weld monitoring rule applied to a result of computation using a function of a measured weld part gap schedule;
• and
• configuring a weld system by a fourth stage of a post welding inspection module for performing an automated inspection of the weld segment and the set of weld parts by using at least one of a camera and a scanner to assess a geometry of the welded part and a length of the welded part and that classifies the weld operation using a classification algorithm that evaluates a fusion of the high-resolution data and the low-resolution data and the adjusted weld schedule.

A welding apparatus, comprising:

• a welding unit configured to:
• in a first stage comprising a scanning device, scan a workpiece comprising a set of weld parts to generate a three-dimensional (3D) profile of a weld target, wherein the 3D profile captures matching imperfections caused by a meeting of the set of weld parts when performing a weld operation for joining of the set of weld parts;
• in a second stage comprising a monitoring device, monitor the weld operation to generate a high-resolution data of measurements of the weld operation;
• wherein the first stage further comprises the monitoring device configured to determine a weld schedule based on the 3D profile of the weld target, and to adjust the weld schedule while the weld operation is in progress to adapt to a predicted distortion in a shape of the weld, the predicted distortion is based on the 3D profile of the target weld and sensed distortion during the weld operation resulting from a combination of forces caused by a weld between the set of weld parts and a clamping force exerted on the workpiece;
• wherein the second stage further comprises a plurality of sensors configured to sense a set of components associated with the weld operation to generate high-resolution data of measurements from direct and indirect sensing of measurements of the set of components associated with the weld operation in contrast to a low-resolution data of measurements provided by a weld controller, wherein:
• at least one or more of the plurality of sensors to provide indirect measurements of the weld operation comprise a microphone, a strain gauge sensor, and a welding reaction force sensor,
• the microphone is configured to monitor ultrasonic frequencies and audible range frequencies of noises associated with the weld operation to determine whether a weld segment is compliant,
• the strain gauge sensor is configured to measure a set of measurements exhibited by the weld part during the weld operation to determine a warping of the weld part and whether the warping of the weld part is beyond a compliant level, the strain gauge sensor being attached to the weld part, and
• the welding reaction force sensor is configured to determine a strength of the weld segment in contrast to the clamping force applied to the weld part;
• in a third stage comprising a processing monitoring module, qualify the weld segment formed by the weld operation based on a weld monitoring rule applied to a result of computation using a function of a measured weld part gap schedule;
• and
• in a fourth stage comprising a post welding inspection module, perform an automated inspection of the weld segment and the set of weld parts by using at least one of a camera and a scanner to assess a geometry of the welded part and a length of the welded part and that classifies the weld operation using a classification algorithm that evaluates a fusion of the high-resolution data and the low-resolution data and the adjusted weld schedule.