# US 2023/0056400 A1 · Systems, methods, and apparatuses, of an arc welding (aw) process and quality monitoring > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2023/0056400 A1 - Document ID: US20230056400A1 - Status: Published application - Kind: A1 - Application number: 17/405,433 - Filed: 2021-08-18 - Published: 2023-02-23 - Earliest claimed: 2021-08-18 - Assignees: GM Global Technology Operations LLC - Applicants: GM Global Technology Operations LLC - Inventors: Debejyo Chakraborty; Miguel Arturo Saez; John Patrick Spicer; Pei-chung Wang; Spyros P. Mellas; Wayne Cai; James M. Ward - Web page: https://patentgrep.com/patent/US20230056400A1 ## CPC - B23K 9/0956: {using sensing means, e.g. optical} - B23K 31/003: {relating to controlling of welding distortion} - B23K 9/0953: {using computing means} - B23K 9/125: {Feeding of electrodes (for stabilising arc B23K9/073)} - B23K 31/125: {Weld quality monitoring} - B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM ## Abstract Systems, methods, and apparatuses of a welding system are disclosed and include a first stage of a scanning device for scanning weld parts to generate a three-dimensional (3D) profile of a weld target wherein the 3D profile captures matching imperfections of a meeting together of the set of weld parts when performing the weld operation; and the second stage of a monitoring device to monitor the weld operation and to generate a data of high-resolution measurements of the weld operation; wherein the first stage further includes the monitoring device determining a weld schedule based on the 3D profile, and to adjust the weld schedule while the weld operation progresses to adapt to predicted distortion based on the 3D profile and to sensed distortion; wherein the second stage further includes a plurality of sensors to sense a set of components associated with the weld operation to generate high-resolution data of measurements. ## Claims ### Claim 1 A weld system comprising: 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 a weld operation for joining the set of weld parts; and a second stage of a monitoring device to 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 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; 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. ### Claim 2 (depends on 1) The weld system of claim 1, further comprising: wherein in the second stage, the plurality of sensors that provides the high-resolution data of measurements comprises at least one or more of a set of sensors to provide direct measurements of the weld operation of a high-resolution current sensor, a high-resolution voltage monitor sensor, and a high-resolution flow sensor. ### Claim 3 (depends on 2) The weld system of claim 2, further comprising: wherein in the second stage, the plurality of sensors that provides the high-resolution data of measurements comprises at least one or more of the plurality of sensors to provide indirect measurements of the weld operation of a microphone, a vibration meter, a plasma sensor, an ultra-violet sensor, a strain gauge sensor, a welding reaction force sensor, an electromagnetic spectrometer, a wire feed sensor, and an infrared camera. ### Claim 4 (depends on 1) The weld system of claim 1, further comprising: wherein the first stage further comprises a sensor comprising a wire to enable by a touch action that impinges at least one weld part of the set of weld parts, to determine a weld part position prior to the weld operation wherein a weld part experiences the clamping force that holds together each weld part of the set of weld parts, and to measure by a tactile sense a change in the shape of the weld part position to determine the distortion in shape of the weld part; and wherein the second stage further comprises the sensor that contains the wire wherein the wire is configured as a consumable electrode that advances to the weld part to deposit a weld bead to form a weld segment of the weld between the set of weld parts and is further configured as a wire feed sensor to provide a measured melt rate of the consumable electrode in the weld operation. ### Claim 5 (depends on 3) The weld system of claim 3, further comprising: 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; and 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 wherein the strain gauge sensor is attached to the weld part. ### Claim 6 (depends on 5) The weld system of claim 5, further comprising: 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. ### Claim 7 (depends on 6) The weld system of claim 6, further comprising: a third stage of the weld system comprising a processing monitoring module configured to 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. ### Claim 8 (depends on 7) The weld system of claim 7, further comprising: the process monitoring module is configured to combine high and low-resolution data from the plurality of sensors and the weld controller to determine a trajectory of a robotic device implemented in the weld operation. ### Claim 9 (depends on 8) The weld system of claim 8, further comprising: a fourth stage of the weld system comprising a post welding inspection module to perform an automated inspection based on an adjusted schedule of the weld segment and the set of weld parts, and by fusing together the high and low-resolution data for quality analysis, to determine if a weld joint is stable, and the weld segment is compliant wherein the quality analysis uses a rule-based schema and a classification algorithm that receives input of fused high and low-resolution data for qualifying and classifying the weld joint. ### Claim 10 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. ### Claim 11 (depends on 10) The method of claim 10, further comprising: configuring, in the second stage, the plurality of sensors for providing the high-resolution data of measurements by at least one or more of a set of sensors providing direct measurements of the weld operation comprising a high-resolution current sensor, a high-resolution voltage monitor sensor, and a high-resolution flow sensor. ### Claim 12 (depends on 11) The method of claim 11, further comprising: configuring, in the second stage, the plurality of sensors for providing the high-resolution data of measurements by at least one or more of the plurality of sensors providing indirect measurements of the weld operation comprising a microphone, a vibration meter, a plasma sensor, an ultra-violet sensor, a strain gauge sensor, a welding reaction force sensor, an electromagnetic spectrometer, a wire feed sensor, and an infrared camera. ### Claim 13 (depends on 10) The method of claim 10, further comprising: configuring a sensor of the first stage comprising a wire for enabling by a touch action that impinges at least one weld part of the set of weld parts, for determining a weld part position prior to the weld operation wherein a weld part experiences the clamping force that holds together each weld part of the set of weld parts, and for measuring by a tactile sense a change in the shape of the weld part position to determine the distortion in shape of the weld part; and configuring by the sensor of the second stage that contains the wire wherein the wire is configured as a consumable electrode that advances to the weld part to deposit a weld bead to form the weld segment of the weld between the set of weld parts and is further configured as a wire feed sensor for providing a measured melt rate of the consumable electrode in the weld operation. ### Claim 14 (depends on 12) The method of claim 12, further comprising: 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; and 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. ### Claim 15 (depends on 14) The method of claim 14, further comprising: configuring a third stage of the weld system comprising a processing monitoring module configured 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. ### Claim 16 (depends on 15) The method of claim 15, further comprising: configuring the process monitoring module for combining high and low-resolution data from the plurality of sensors and the weld controller for determining a trajectory of a robotic device implemented in the weld operation. ### Claim 17 (depends on 16) The method of claim 16, further comprising: configuring a fourth stage of the weld system comprising a post welding inspection module to perform an automated inspection based on an adjusted weld schedule of the weld segment and the set of weld parts, and by fusing together the high and low-resolution data for quality analysis, to determine if a weld joint is stable, and the weld segment is compliant wherein the quality analysis uses a rule-based schema and a classification algorithm that receives input of fused high and low-resolution data for qualifying and classifying the weld joint. ### Claim 18 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. ### Claim 19 (depends on 18) The welding apparatus of claim 18, further comprising: wherein the welding unit is further configured to: in the second stage, measure by the plurality of sensors the high-resolution data of measurements by at least one or more of a set of high-resolution sensors to provide direct measurements of the weld operation comprising a high-resolution current sensor, a high-resolution voltage monitor, and a high-resolution flow sensor; and in the second stage, measure by the plurality of sensors the high-resolution data of measurements by at least one or more of the plurality of sensors to provide indirect measurements of the weld operation comprising a microphone, a vibration meter, a plasma sensor, an ultra-violet sensor, a strain gauge sensor, a welding reaction force sensor, an electromagnetic spectrometer, a wire feed sensor, and an infrared camera. ### Claim 20 (depends on 19) The welding apparatus of claim 19, further comprising: wherein the welding unit is further configured to: in the first stage, configure a sensor comprising a wire, to enable by a touch action of wire that impinges at least one weld part of the set of weld parts, to determine a weld part position of the weld part prior to the weld operation wherein a weld part experiences the clamping force that holds together each weld part of the set of weld parts, and to measure by a tactile sense a change in the shape of the weld part position to determine the distortion in shape of the weld part; and in the second stage configure the sensor that contains the wire, configure the wire as a consumable electrode that advances to the weld part to deposit a weld bead to form the weld segment of the weld between the set of weld parts and is further configured as a wire feed sensor to provide a measured melt rate of the consumable electrode in the weld operation.