Weld testing system and method for a welding assembly

A non-destructive weld testing system for testing spot welds performed by welding electrodes of a welding machine, the weld testing system comprising:

• a weld monitoring tool monitoring at least one weld characteristic of the spot welds, the weld monitoring tool generating weld data based on the at least one weld characteristic;
• a weld analysis tool analyzing the weld data to determine a weld quality of each spot weld based on analysis criteria;
• and
• a non-destructive weld testing tool configured to test spot welds, wherein the weld testing system causes the weld testing tool to target testing of spot welds determined by the weld analysis tool to have a weld quality beyond a threshold weld quality, the weld testing tool generating weld test data based on testing results, the weld testing tool providing feedback to the weld analysis tool correlating to the weld test data, the weld analysis tool updating the analysis criteria based on the weld test data.

A method of non-destructive weld testing spot welds performed by welding electrodes of a welding machine, the method comprising:

• monitoring at least one weld characteristic of the spot welds;
• generating weld data based on the at least one weld characteristic;
• analyzing the weld data to determine a weld quality of each spot weld based on analysis criteria to determine spot welds that are anomalies;
• and
• testing spot welds determined to be anomalies;
• generating weld test data based on testing results of the tested spot welds;
• and
• providing feedback correlating to the weld test data to update the analysis criteria based on the weld test data.