Welding apparatus and methods for using ultrasonic sensing

A welding apparatus using ultrasonic sensing, comprising:

• a moveable welder having a selectively adjustable welding head for forming a partially completed weld in a weld seam defined between adjoining metal substrates;
• an ultrasonic assembly borne by the moveable welder for generating an ultrasonic signal which is directed toward the partially completed weld, and wherein the ultrasonic signal strikes the partially completed weld and is reflected back in the direction of the ultrasonic assembly;
• a timing assembly for calculating an average time that it takes for the ultrasonic signal to be transmitted and returned to the ultrasonic assembly;
• and
• a controller electrically coupled with the timing assembly, and which determines from the average time, a distance that the ultrasonic assembly is from the partially completed weld.

A welding apparatus using ultrasonic sensing, comprising:

• a moveable welder having a selectively adjustable welding head for forming a partially completed weld in a weld seam defined between adjoining metal substrates;
• an ultrasonic assembly borne by the moveable welder for generating an ultrasonic signal along a surface of the metal substrates, and which is directed toward the partially completed weld, and wherein the ultrasonic signal strikes the partially completed weld and is reflected back in the direction of the ultrasonic assembly;
• a timing assembly for calculating an average time that it takes for the ultrasonic signal to be transmitted and returned to the ultrasonic assembly;
• and
• a controller electrically coupled with the timing assembly and which utilizes the average time to calculate a distance that the ultrasonic generator is from the partially completed weld, and position the welding head to track the partially completed weld.

A welding apparatus using ultrasonic sensing, comprising:

• a movable welder having a selectively adjustable welding head for forming a partially completed weld in a metal substrate;
• an ultrasonic assembly borne by the moveable welder for generating an ultrasonic signal which is directed toward the partially completed weld, and wherein the ultrasonic signal is reflected off a bottom surface of the metal substrate before striking the partially completed weld, and wherein the ultrasonic signal strikes the partially completed weld and is reflected back in the direction of the ultrasonic assembly;
• a timing assembly for calculating an average time that it takes for the ultrasonic signal to be transmitted and returned to the ultrasonic assembly;
• and
• a controller electrically coupled with the timing assembly and determining from the average time, a distance that the ultrasonic assembly is from the partially completed weld.

A welding method using ultrasonic sensing, comprising:

• providing a moveable welder having a selectively adjustable welding head for forming a partially completed weld;
• providing an ultrasonic assembly borne by the moveable welder for generating an ultrasonic signal which is directed toward the partially completed weld, and wherein the ultrasonic signal strikes the partially completed weld and is reflected back in the direction of the ultrasonic assembly;
• calculating an average time that it takes for the ultrasonic signal to be transmitted and returned to the ultrasonic assembly;
• and
• determining from the average time, a distance that the welding head is from the partially completed weld.