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Process Control Module


The main goal of the RLW Process Control module is to have in-process monitoring and simultaneous
joint quality evaluation as measured by key joint quality indicators: penetration, s-value (joint width)
and top-concavity by using in-process real-time data (e.g., plasma, temperature and back-radiation).
The state-of-art solution to this problem assumes that the joint’s quality can be inferred by comparing
signal templates against the measured signal. Although this can be implemented in-process during
welding, it is sensitive to interpretation and does not directly indicate quality of joints.
The developed tool extends the state-of-art by providing a novel approach for linking in-line
process monitoring signals with process KPIs. The tool involves two steps: (i) in-process radiation
monitoring (i.e., using photodiode); & (ii) analytics correlating data to joint performance. To develop
the analytical model the process signal is filtered into visible light, temperature and back-reflection
using photodiode sensor. The filtered signal is then used to extract significant features, correlated to
joint performance. Optimum process parameters are then calculated which satisfy cycle time (welding
speed) or minimum power demand.


OBJECTIVE

To develop production tools for minimizing the ramp-up time and ensuring good weld quality during production through process monitoring and control.

CAPABILITY

  • Monitor in-process weld and part quality.
  • Fixture root cause analysis.
  • Adjust laser parameter.

IMPACT

  • Lead-time minimization.
  • Enhanced weld quality.
  • Reduction of NDT tests.
  • Closed-loop process quality adjustment.

APPLICATION

  • Ramp-up.
  • Production.

TOOLS

(i) SmartLaser Process Monitoring Integration Tool

(ii) Weld Quality Performance Evaluator Tool

(iii) Process Monitoring and Weld Fault Classification Tool