Abstract: A method for determining the quality of a weld bead includes producing a weld bead along a work surface during a welding process and scanning the weld bead with a vision system to obtain positional data points for defining a weld bead profile. The weld bead has a weld toe zone or region, which is formed at the interface between the weld bead and the work surface. A curve fit is determined for the weld bead profile bases on the positional data points obtained by the laser scan vision system. The toe radius is derived bases on the curve fit and is then compared to a first predetermined limit and a second predetermined limit, greater than the first predetermined limit, to determine the quality of the weld bead. If the toe radius is less than the first predetermined limit or greater than the second predetermined limit, the welding process is modified to produce a weld bead with a toe radius that falls within the desired range.

Abstract: A method for sensing and controlling the weld quality of gas metal arc welding employs sampling of the welding current and voltage signals and making determinations of the weld quality state based on information embedded in those signals. The signals are processed such that the quality of the weld can be determined and the appropriate steps are taken to respond to the detected quality level. If the quality level is deemed unacceptable the process is terminated and the operator is alerted. The method includes determinations based on the standard deviation of the electrical signal, the summed power spectrum of the electrical signal, and/or the average absolute value of the time derivative of the electrical signal.

Abstract: A method for determining distortion of a member which results from the member being subjected to a welding operation is disclosed. The method includes the steps of (1) locating the member so that the member assumes a first position, (2) obtaining first data measurements of the member while the member is located in the first position, (3) performing the welding operation on the member whereby the member distorts and assumes a second position, (4) obtaining second data measurements of the member while the member is located in the second position, and (5) calculating distortion of the member based on the first data measurements and the second data measurements. An apparatus for determining distortion of a member which results from the member being subjected to a welding operation is also disclosed.

Abstract: A method for sensing and controlling the weld quality of gas metal arc welding employs sampling of the welding current and voltage signals and making determinations of the weld quality state based on information embedded in those signals. The signals are processed such that the quality of the weld can be determined and the appropriate steps are taken to respond to the detected quality level. If the quality level is deemed unacceptable the process is terminated and the operator is alerted. The method includes determinations based on the standard deviation of the electrical signal, the summed power spectrum of the electrical signal, and/or the average absolute value of the time derivative of the electrical signal.