IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
US-0623249
(2009-11-20)
|
등록번호 |
US-8723078
(2014-05-13)
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발명자
/ 주소 |
- Mazumder, Jyoti
- Lee, Seung H.
|
출원인 / 주소 |
- The Regents of The University of Michigan
|
대리인 / 주소 |
Harness, Dickey & Pierce, P.L.C.
|
인용정보 |
피인용 횟수 :
3 인용 특허 :
3 |
초록
▼
A method of monitoring a welding process, comprising detecting a selected portion of a light spectrum of plasma plume of a fusion welding process with a photo detector, processing the detected portion of the spectrum, comparing the detected portion of the spectrum with an expected spectra to determi
A method of monitoring a welding process, comprising detecting a selected portion of a light spectrum of plasma plume of a fusion welding process with a photo detector, processing the detected portion of the spectrum, comparing the detected portion of the spectrum with an expected spectra to determine whether a weld is acceptable, providing a signal to a welder control, and adjusting the weld process based on the signal.
대표청구항
▼
1. A method of monitoring a welding process, comprising: spatially and temporally detecting a selected portion of a light spectrum of plasma plume of a fusion welding process with a photo detector;processing the detected portion of the spectrum to determine a line intensity, an electron temperature,
1. A method of monitoring a welding process, comprising: spatially and temporally detecting a selected portion of a light spectrum of plasma plume of a fusion welding process with a photo detector;processing the detected portion of the spectrum to determine a line intensity, an electron temperature, and relative quantities of iron and zinc in the plasma plume;comparing the detected portion of the spectrum with an expected spectra to determine whether a weld is acceptable;providing a signal to a welder control, the signal representing the presence of a weld defect; andadjusting the weld process based on the signal to correct the weld defect. 2. The method of claim 1, further comprising detecting a vaporized material that expands away from a welding melt pool surface, wherein the vapor is indicative of at least one of an underfill defect condition, a bead separation defect condition and a loss of a coating defect condition. 3. The method of claim 1, further comprising filtering the spectrum of the plasma plume with an optical filter interposed between the plasma plume and the photo detector to provide a spectral region of interest to the photo detector. 4. The method of claim 1, further comprising positioning a focusing lens near the plasma plume at a range of approximately 2 inches to 5 meters away, wherein the focusing lens is optically connected to the photo detector. 5. The method of claim 1, further comprising positioning a focusing lens near the plasma plume and at an outer edge of the effective heat of a welding process, wherein the focusing lens is optically connected to the photo detector. 6. The method of claim 1, further comprising maintaining a fixed distance between the plasma plume and a focusing lens. 7. The method of claim 1, further comprising detecting a differential amount of energy between a first energy state and a second energy state to determine electron temperature. 8. The method of claim 1, further comprising recording at least the line intensity, the electron temperature and the ratio of iron and zinc in the plasma plume. 9. The method of claim 1, further comprising processing data from at least one of the line intensity data set, the electron temperature data set and the relative quantities of iron and zinc in the plasma plume data set, wherein the data is used to predict an in-process weld quality. 10. The method of claim 1, further comprising communicating bi-directionally between a first computer configured to analyze and predict a welding plasma plume with a second computer configured to control and monitor various parameters on a welding system. 11. A welding system comprising: a metal substrate;a welder, wherein at least one material is fused by a weld, wherein the weld creates a plasma plume emission;a welding controller;a monitoring system, wherein the monitoring system includes at least one optical sensor;a computing device, wherein the computing device is configured to calculate a ratio of materials in the plasma plume emission, and wherein the computing device measures and plots at least one spectral line intensity, at least one electron temperature and at least one ratio that is recorded; anda feedback loop, wherein the feedback loop provides the welder control and an operator with a weld quality result; andwherein the monitoring system is configured to generate a signal that represents a weld defect based on a spectral analysis of light in the plume emission and control the weld controller to correct the weld defect in accordance with the signal. 12. The welding system according to claim 11, further comprising a focusing lens, wherein the focusing lens is at least one of an optical focusing lens and a tunable collimator, and wherein the focusing lens gathers light from the plasma plume emission to detect at least one of an underfill defect condition, a bead separation defect condition and a loss of coating defect condition. 13. The welding system according to claim 11, further comprising an optical filter, wherein the optical filter receives light from a focusing lens to filter a received light spectrum prior to transmission into a photo detector, wherein the optical filter is configured to pass light corresponding to at least one of zinc and iron. 14. The welding system according to claim 11, further comprising a photo detector, wherein the photo detector is at least one of an ultra-violet, infra-red and visible light detector. 15. The welding system according to claim 14, wherein the photo detector includes an integrated amplifier for converting received light spectra into an electrical signal. 16. The welding system according to claim 11, wherein the metal substrate is a zinc-coated steel. 17. The welding system according to claim 11, wherein the welding system includes at least one of a metal fusing laser welder and a metal fusing arc welder. 18. The welding system according to claim 11, wherein the computing device includes feedback controller having bi-directional communication with a second computing device. 19. The welding monitoring system according to claim 11, wherein a spectral data of the plasma plume is recorded with at least a 1 millisecond integration time by the optical sensor. 20. The welding system according to claim 11, wherein the optical sensor includes an in-situ sensor and can determine in process defects of a weld bead. 21. A method of monitoring a welding process, comprising: spatially and temporally detecting a selected portion of a light spectrum of plasma plume of a fusion welding process with a photo detector;processing the detected portion of the spectrum to determine a line intensity, an electron temperature, and relative quantities of iron and zinc in the plasma plume;recording at least the line intensity, the electron temperature and the ratio of iron and zinc in the plasma plume;comparing the detected portion of the spectrum with an expected spectra to determine whether a weld is acceptable;predicting an in-process weld quality based at least in part on the line intensity, the electron temperature, and the relative quantities of iron and zinc;generating a signal representing the weld quality, the signal representing the presence of a weld defect; andadjusting the weld process based on the signal to correct the weld defect.
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