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;
• and
• configuring of the weld system by a second stage of a monitoring device for monitoring the weld operation and for generating data of high-resolution 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;
• and
• 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.

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;
• and
• in a second stage comprising a monitoring device, monitor the weld operation and to generate a data of high-resolution measurements of the weld operation;
• wherein the first stage further comprises the monitoring device 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 based on the 3D profile of the target weld, and by 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.