Weld defect detection systems and methods for laser hybrid welding
AssigneeIllinois Tool Works Inc.
InventorBruce Patrick Albrecht
Life of this patent
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Abstract
Laser hybrid welding systems adapted to identify and/or fix a weld defect occurring during a laser hybrid welding process are provided. Embodiments of the laser hybrid welding system may include one or more devices that provide feedback to a controller regarding one or more weld parameters. One embodiment of the laser hybrid welding system includes sensors that are adapted to measure the weld voltage and/or amperage during the welding process and transmit the acquired data to the controller for processing. Another embodiment of the laser hybrid welding system includes a lead camera and a lag camera that film an area directly in front of the weld location and directly behind the weld location.
Claims22
A laser hybrid welding system, comprising:
- a welder configured to perform a laser hybrid welding operation in which a workpiece is heated by a laser in a laser welding process and filler metal is added by an arc welding process;
- a sensor configured to acquire data regarding a parameter of the laser hybrid welding operation;
- and
- a controller communicatively coupled to the sensor and configured to receive the acquired data from the sensor, to determine whether the acquired data is indicative of a welding defect, and if the acquired data is indicative of a welding defect, to determine which of the laser welding process, the arc welding process, or both, should be altered to fix the welding defect, and to output a control signal that directs the laser hybrid welding system to automatically alter the laser, the arc welding process, or both, during the laser hybrid welding operation to coordinate to attempt to fix the welding defect.
A controller for a laser hybrid welding system, comprising:
- interface circuitry configured to receive data regarding a parameter of a laser hybrid welding operation and to output one or more control signals;
- and
- a processor communicatively coupled to the interface circuitry and configured to receive the data from the interface circuitry and to process the received data to determine if a weld defect has occurred, wherein if the processor determines that a weld defect has occurred, the processor is further configured to transmit a control signal to the interface circuitry that encodes instructions for the repair of the weld defect;
- wherein the interface circuitry is configured to receive and process the control signal from the processor and, if the weld defect is a burn-through with a size exceeding a preset threshold, to output the one or more control signals to direct a laser to turn off and to direct an arc welder to remain on to fix the burn-through.
A laser hybrid welding system, comprising:
- a welder configured to perform a laser hybrid welding operation in which a workpiece is heated by a laser and filler metal is added by an arc welding process;
- a sensor comprising a leading camera configured to record a first image of a pre-weld area and a following camera configured to record a second image of a post-weld area and being configured to acquire data regarding a parameter of the laser hybrid welding operation;
- and
- a controller communicatively coupled to the sensor and configured to receive the acquired data from the sensor, to determine whether the acquired data is indicative of a welding defect, and if the acquired data is indicative of a welding defect, to log the welding defect as an error in an associated memory.
A controller for a laser hybrid welding system, comprising:
- interface circuitry configured to receive data regarding a parameter of a laser hybrid welding operation and to output one or more control signals;
- and
- a processor communicatively coupled to the interface circuitry and configured to receive the data from the interface circuitry and to process the received data to determine if a weld defect has occurred, wherein if the processor determines that a weld defect has occurred, the processor is further configured to transmit a control signal to the interface circuitry that encodes instructions for the repair of the weld defect;
- wherein the interface circuitry is configured to receive and process the control signal from the processor and, if the weld defect exceeds a preset length, the interface circuitry outputs, in the stated order, a control signal that directs a laser and an arc welder to turn off, a control signal that directs a torch positioner to a starting location of the weld defect, a control signal that directs the laser and the arc welder to turn on, and a control signal that directs the torch positioner to run another pass over the location of the weld defect.
Dependencies are inferred from the claim text.