Incipient Wear Detection of Welding Gun Secondary Circuit by Virtual Resistance Sensor Using Mahalanobis Distance.

Wear of the secondary of the welding gun, caused by mechanical fatigue or due to a bad parameterization of the welding points, causes an increase in quality problems such as non-existent welds or a reduced weld nugget size. In addition to quality problems, this defect causes production stoppages that affect the final cost of the manufactured part. Different studies have focused on evaluating the importance of different welding parameters, such as current, in the final quality of the welding nugget. However, few studies have focused on preventing weld command parameters from degrading or changing. This investigation seeks to determine the wear of the secondary circuit to avoid variability in the current supplied to the welding point caused by this defect and the increase in circuit resistance, especially in industrial environments. In this work, a virtual sensor is developed to estimate the resistance of the welding arm based on previous research, which has shown the possibility of detecting secondary wear by analysing the duty cycle of the power circuit. From the data of the virtual sensor, an anomaly detection method based on the Mahalanobis distance is developed. Finally, an integral system for detecting secondary wear of welding guns in real production lines is presented. This system establishes performance thresholds based on the analysis of the Mahalanobis distance distribution, allowing monitoring of the secondary circuit wear condition after each welding cycle. The results obtained show how the system can detect incipient wear in welding guns, regardless of which part of the secondary the wear occurs, improving decision-making and reducing quality problems.

An Unsupervised Condition Monitoring System for Electrode Milling Problems in the Resistance Welding Process.

Resistance spot welding is one of the most widely used metal joining processes in the manufacturing industry, used for structural body manufacturing, railway vehicle construction, electronics manufacturing, battery manufacturing, etc. Due to its wide use, the quality of welded joints is of great importance to the manufacturing industry, as it is critical for ensuring the integrity of finished products, such as car bodies, that withstand high levels of stress. The quality of the welding is influenced both by the programming of the welding and by the good condition of the mechanical part that carries out the welding. These mechanical factors, such as electrode geometry and wear, degrade over time. As the welding points are made, the geometry and properties of the electrodes change, so they undergo a milling process to remove impurities and return them to their initial geometry. Sometimes the milling is deficient, and the electrode continues to wear, causing welding problems such as loose spots and metal spatter. This article presents a method for condition monitoring of the milling process and weld wear based on existing data in real production lines. The use of unsupervised clustering methods is proposed to perform a check by which, using current and resistance data, the electrode wear is grouped. Specifically, a method using multidimensional k-means for the condition monitoring of electrode wear is established. This research gives a real and applicable solution for reducing the quality problems caused by milling defects and electrode wear in the production lines of high-production manufacturing industries, presenting a system for sending alarms based on the behavior of welding variables.

Real-Time Condition Monitoring System for Electrode Alignment in Resistance Welding Electrodes.

Electrode misalignment, produced by mechanical fatigue or bad adjustments of the welding gun, leads to an increase in expulsions, deformations and quality problems of the welding joints. Different studies have focused on evaluations of the influence of a misalignment of the electrodes and the final quality of the weld nugget. However, few studies have focused on determining a misalignment of the electrodes to avoid problems caused by this defect, especially in industrial environments. In this paper, a method for performing the condition monitoring of electrode alignment degradation was developed following previous research, which has shown the relationship between the misalignment of short-circuited electrodes and the magnetic field generated by them. This method was carried out by means of a device capable of measuring the magnetic field. Finally, an integral system for the detection of misalignments in real production lines is presented. This system set behavior thresholds based on the experimentation, allowing the condition monitoring of the alignment after each welding cycle.

Novel wireless sensor system for dynamic characterization of borehole heat exchangers.

The design and field test of a novel sensor system based in autonomous wireless sensors to measure the temperature of the heat transfer fluid along a borehole heat exchanger (BHE) is presented. The system, by means of two special valves, inserts and extracts miniaturized wireless sensors inside the pipes of the borehole, which are carried by the thermal fluid. Each sensor is embedded in a small sphere of just 25 mm diameter and 8 gr weight, containing a transceiver, a microcontroller, a temperature sensor and a power supply. A wireless data processing unit transmits to the sensors the acquisition configuration before the measurements, and also downloads the temperature data measured by the sensor along its way through the BHE U-tube. This sensor system is intended to improve the conventional thermal response test (TRT) and it allows the collection of information about the thermal characteristics of the geological structure of subsurface and its influence in borehole thermal behaviour, which in turn, facilitates the implementation of TRTs in a more cost-effective and reliable way.

Transmission Attenuation Power Ratio Analysis of Flexible Electromagnetic Absorber Sheets Combined with a Metal Layer.

Electromagnetic noise absorber sheets have become a solution for solving complex electromagnetic interference (EMI) problems due to their high magnetic losses. This contribution is focused on characterizing a novel structure that is based on an absorber film with a metal layer attached on its top side. Two different absorber compositions were combined with Al and Cu metal layers in order to study the improvement on the performance of these structures, depending on the complex permeability, absorber film thickness, and type of metal. The transmission attenuation power ratio of the absorber films is analyzed and compared to the performance of absorber and metal structures. The measurement procedure is carried out attaching the films into a microstrip line that has been designed based on IEC standard (IEC 62333-2). This test fixture is employed as a transmission line to simulate a general noise path. The performance of absorber composites to filter electromagnetic noise is evaluated through analyzing S21 and S11 parameters. This is carried out with the aim of finding out in which conditions the absorption loss is improved when a metal layer is attached. In addition, the possible re-radiation effect, due to the magnetic field that is generated by the eddy currents induced in the metal layer, is examined.

Characterization of Different Cable Ferrite Materials to Reduce the Electromagnetic Noise in the 2-150 kHz Frequency Range.

The gap of standardization for conducted and field coupled electromagnetic interferences (EMI) in the 2-150 kHz frequency range can lead to Electromagnetic Compatibility (EMC) problems. This is caused by power systems such as Pulse Width Modulation (PWM) controlled rectifiers, photovoltaic inverters or charging battery units in electric vehicles. This is a very important frequency spectral due to interferences generated in a wide range of devices and, specifically, communication problems in the new technologies and devices incorporated to the traditional grid to convert it into a Smart Grid. Consequently, it is necessary to provide new solutions to attenuate this kind of interference, which involves finding new materials that are able to filter the electromagnetic noise. This contribution is focused on characterizing the performance of a novel material based on nanocrystalline and comparing it to most common material compositions such as MnZn and NiZn. This research is carried out from the point of view of the manufacturing process, magnetic properties and EMI suppression ability. This last item is carried out through two analysis procedures: a theoretical method by determining the attenuation ratio by measuring impedance parameter and proposing a new empirical technique based on measuring directly the insertion loss parameter. Therefore, the main aim of this characterization process is to determine the performance of nanocrystalline compared to traditional cable ferrite compositions to reduce the interferences in this controversial frequency range. From the results obtained, it is possible to deduce that nanocrystalline cable ferrite provides the best performance to filter the electromagnetic noise in the 2-150 kHz frequency range.