Energy monitoring technology has been used to monitor the welding quality of aluminum alloy, stainless steel, carbon steel, and structural steel in medium frequency spot welding machines, and validated against tear or low-magnification inspections, proving the effectiveness of energy method.
Monitoring Technology and Application:
Applicability of Different Forms of Energy Integration:
Two commonly used monitoring forms can be switched and chosen arbitrarily for monitoring. In practical applications, a reasonable choice is needed. One form is the integration of current over time, which is suitable for occasions where electrical parameters such as current and time are prone to change, such as factors causing changes in welding current due to changes in power supply voltage and secondary circuit of the machine. However, it is not suitable for occasions prone to electrode force and current diversion. Additionally, this method can only be valid under conditions where the resistance in the welding area is basically constant, making it more suitable for aluminum alloy and stainless steel.
Monitoring Sensitivity:
To compare the monitoring effects of different energy monitoring forms, the issue of monitoring sensitivity is raised. In engineering technology, a relative concept is adopted, where the percentage change in fusion core diameter due to a 1mm variation is taken as the evaluation index of monitoring sensitivity. The higher the percentage change in energy value, the higher the sensitivity.
Before monitoring the spot welding quality of a certain product, the relationship between energy value and fusion core diameter and shear strength should be determined based on process experiments, and the energy control zone should be calculated. The energy monitoring instrument should have preset switches for upper and lower limits of energy (preset based on the upper and lower limits of the energy control zone). If the measured energy value exceeds the control range, the instrument will alarm, indicating the unreliability of the quality, and appropriate actions should be taken.
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Post time: Mar-28-2024