Gm Global Technolgoy Operations, Inc.

Dixon Cleveland

Gregory L Nagel

James R Havens

Basil A Decina, Jr

Albert F Houchens

Balarama Vempaty Murty

David M Sidlosky

William C Jenuwine

Anthony Lee

Dale K Watney

A method and apparatus are disclosed for analyzing the dynamic resistance of a resistance spot welding process to determine the time of an expulsion event and use that time as the weld completion time for controlling weld termination via a weld feedback signal, controlling automatic current stepping, and identifying maintenance needs. A preconditioning pulse is used to stabilize the weld process and aid in obtaining interpretable resistance information. After an initial blanking period the resistance curve is analyzed by calculating first and second derivative values and applying several algorithms that make possible the computer recognition of characteristic resistance curve shapes resulting from weld expulsion under good geometry, bad geometry and edge weld conditions.

Method and apparatus for monitoring and controlling resistance spot

During a weld period the weld parameters are monitored and data representing the weld resistance curve and the power curve are acquired and stored for analysis by a suitably programmed computer. The derivative of R, R is calculated and stored and the function is divided by power P to obtain R/P. The resistance curve is searched to obtain the maximum value R.sub.m which occurs during the heating phase and the function R/P is searched prior to the time of R.sub.m to find the maximum of that curve representing the highest rate of resistance increase. Then the R/P curve is searched subsequent to its maximum to determine when the function reaches a specified percentage of the maximum. That value occurs at the knee of the resistance curve and approximates the onset of melting in the weld. A prediction of whether a weld is a nugget or a sticker is made by calculating the ratio of weld energy after the onset of melting to the total weld energy, the ratio of the resistance drop after the resistance peak to the peak resistance, and then a weighted sum of the energy ratio and resistance drop ratio. An edge weld geometry is detected by calculating from the resistance and power curves the weld energy during the period of expulsion, if any, divided by the cumulative energy between the onset of melting and the end of expulsion, a measure of expulsion intensity based on the maximum degree of resistance inflection, and then a weighted sum of the energy value and the inflection value.

Method and apparatus for detecting the onset of melting in a resistance

Method and apparatus for predicting and controlling the quality of a

Method and apparatus for detecting edge welds during resistance spot

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Vienna, VA, United States of America

Dixon Cleveland