ABB Ultrasonic Spot Welding Quality Inspection
— ABB Ultrasonic spot welding quality inspection MARCH 2022 Robotic spot welding quality inspection solution based on ultrasonic technology ABB Robotics, Body-in-White Global Solution Center Copyright 2021 ABB. All rights reserved. Document ID.: 9AKK107991A6049 Rev.: 02
— Introduction
— Reducing the amount of manual testing Effective and efficient screening of weld spots Automatic Screening of weldspot quality Key message also. Capture trends System advised actions for personnel TOTAL AMOUNT OF WELD SPOTS INCREASING COST AND DELAY FROM TIME OF MANUFACTURING WELD DATA MONITORING March 7, 2022 Slide 3 ULTRASONIC INSPECTION (AUTOMATED) VISUAL INSPECTION ULTRASONIC INSPECTION (MANUAL) (OPERATOR) DESTRUCTIVE TESTING (MANUAL)
— Ultrasonic spot welding quality inspection A solution for automotive industry demands – Low sampling – Time and resource intensive Manual Testing – Long response time – Low repeatability – No systematic traceability of the workpiece quality – Reliable process ABB Ultrasonic spot welding quality inspection – Cost reduction – Fast response time – Repeatability – Data analysis March 7, 2022 Slide 4
— Automated Ultrasonic Inspection of weld spots Ultrasound technology basics Automated robot-guided ultrasonic testing: – Same quality of results as with manual testing – Additional benefits of automation: Cycle time Accuracy Efficiency Reproducibility Automation does not influence the physical principles of ultrasound March 7, 2022 Slide 5
— Ultrasonic spot welding quality inspection
— Ultrasonic spot welding quality inspection Video March 7, 2022 Slide 7
— Ultrasonic spot welding quality inspection Complete Functional Module ready-to-use – Complete robotic solution based on ultrasonic technology, for quality inspection of spot welds – A ready-to-use integrated solution that includes all the components and functionalities required for a fast and accurate inspection: Hardware and Software (Equipment/ Dresspack/ Controller) PHAsisBLU* (from VOGT) ready to go ultrasonic instrument for spot weld and short stick weld inspection, real phased array ultrasonic technology, for quality inspection of spot welds Complete Programming-Wizard for easy and simplified programming and system tuning ABB UltraReporter for reliable data and quality assurance A complete solution for fast and accurate spot welding quality inspection March 7, 2022 Slide 8 *VOGT equipment
— Ultrasonic spot welding quality inspection Protective cover Grinding head Camera Ultrasonic probe Spray head and blow-off unit March 7, 2022 Slide 9 Dimensions: 60x20x53,1cm (LxWxH) Weight: 22,5kg
— Ultrasonic spot welding quality inspection One combined tool – fully integrated solution Functionality – Recognition of weld spot position Design – Automatic removal of weld spatter – Compact – Few disturbed contours – Automatic ultrasonic weld spot inspection – Collision protection housing Specification – Typical cycle time to inspect*: 3-6 sec – High accessibility of the welding points March 7, 2022 Slide 10 * Depending on spot weld quality and according to lab tests
— PHAsisBLU* (VOGT equipment) Ultrasonic measurement device with probe – PHAsisBLU*, ready to go ultrasonic instrument for spot weld and short stick weld inspection, real phased array ultrasonic technology, for quality inspection of spot welds – An instrument built for Ultrasonics applications with robotics as an integrated solution with best technical data: 16/128 Ultrasonic PHASED ARRAY Hardware (16 parallel channels and up to 128 multiplex channels) PHAsis* Spotweld and short stick welds software with inspection plans and a robot interface for bidirectional communication Highest frequency of up to 20 MHz supports spot weld and short stick weld testing Fast pulse repetition rate of 20.000 Hz for effective cycle times March 7, 2022 Slide 11 *VOGT equipment
— Ultrasonic spot welding quality inspection Functionality and process flow Recognition of spot weld position March 7, 2022 Slide 12 Automatic removal of weld spatter Ultrasonic weld spot measurement Capture and visualization of the result
— Automated ultrasonic inspection of weld spots From component to system integration – Modular standard solutions SpotInspect Functional Module Modular Standard System Complete Functional Module Ready-to-Use Application Cells Easy-to-integrate Smart system solutions for high volumes – Hardware and Software (Equipment/ Dresspack/ Controller) – Standardized cell concepts “ready-to-use” – Modular and scalable automation solution based on ABB products – Complete Programming-Wizard for easy and simplified programming and system tuning – Reliable data and quality assurance March 7, 2022 Slide 13 – Capacities up to 8.000 WSPs per day – Considerable cost saving potential through reduction of manual inspection workstations Smart Solutions – Capacities from 8.000 up to 22.000 WSPs per day – Considerable cost saving potential through reduction of manual inspection workstations
— Benefits in all areas Data analysis Support Web-based data visualization/storage Allows analysis of historical data and to see trends like spot welds position and quality Automated notification of suspicious (out of spec.) spot welds Single supplier that guarantees functionality Simulation models available Performance Higher inspection rate High accessibility on testing workpieces Typical cycle time to inspect* 3-6 sec Ultrasonic automated inspection gives 10 times increased capacity relative operator** What are the main benefits ? Operation Easy-to-use and fast start up with programming setup wizard Simple system tuning under running production Solution Complete Functional Module Ready-to-Use Modular and scalable automation solution Coordinated components March 7, 2022 Slide 14 *Depending on spot weld quality and according to lab tests **Estimation measurements based in 1 operator over one year
— Increase in productivity, scalability and flexibility Ultrasonic spot welding quality inspection Customer value proposition Worker requirements -85% Reduction of the laborintensive testing activities Reproducibility 100% Reproducible measurement results through process automation March 7, 2022 Slide 15 *Estimation measurements based in 1 operator over one year High efficiency* Automated inspection gives 10 times increased capacity relative operator Industry 4.0 pioneer 100% Data provision for further optimizations / analyzes
-Recognition of weld spot position -Automatic removal of weld spatter -Automatic ultrasonic weld spot inspection Ultrasonic spot welding quality inspection March 7, 2022 Slide 10 * Depending on spot weld quality and according to lab tests One combined tool -fully integrated solution Specification -Typical cycle time to inspect*: 3-6 sec
1.1 Ultrasonic metal spot welding In ultrasonic metal spot welding, two (or more) metallic partners are joined in a discrete area. It is the most relevant ultrasonic welding technology in power electronics appli-cations, other ultrasonic welding technologies join plastic parts and/or form continuous joints.
6.3 Mechanised/automatic welding 114 6.4 TIG spot and plug welding 115 7 MIG welding 116 7.1 Introduction 116 7.2 Process principles 116 7.3 Welding consumables 130 7.4 Welding procedures and techniques 135 7.5 Mechanised and robotic welding 141 7.6 Mechanised electro-gas welding 143 7.7 MIG spot welding 144 8 Other welding processes 147 8.1 .
foils welding, copper cable bonding, and ultrasonic processing of liquids. The aim of the paper is to present a novel design of an ultrasonic welding generator. 2. Ultrasonic welding machine. Example of an ultrasonic welding machine is presented in Figure 1. Fig. 1. Ultrasonic welding machine.
Unit 9 – Resistance Welding Spot Welding Lap Joint Duration – 3.5 Hours Learning Outcome: By the end of this unit each apprentice will be able to: Read drawing and interpret weld symbol Prepare material for spot welding Set-up spot welding machine Spot weld mild steel lap joi
Ultrasonic welding machines for plastic parts Company foundation Ultrasonic generators Company Development Ultrasonic Welding Technology Foundation of Herrmann Ultrasonics Co. Ltd. China DIALOG process visualization 1961 1969191 1984 1989 2000 2011 1965 1973 1994 Marketability ULTRALINE First digital ultrasonic generator
ABB Control SECRL - 1 2001-06-19 A New Contactor Range from ABB New Generation ABB Contactors. ABB Control SECRL - 2 2001-06-19 The ABB range of A The ABB range of A contactorscontactors A 9, A 12, A 16 A 26, A 30, A 40 A 50, A 63, A 75 A 95, A
Ultrasonic Welding Figure 31.2 (a) Components of an ultrasonic welding machine for making lap welds. The lateral vibrations of the tool tip cause plastic deformation . Typical parts made by flash welding. (d) Some design guidelines for flash welding. Stud Welding Figure 31.15 The sequence of operations in stud welding, commonly used for .
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