How Welding Robots Detect Weld Quality?

As we all know, welding robots are automated intelligent devices utilized for welding production tasks.

Within on-site welding applications in factories, welding robots significantly enhance welding efficiency, define the production cycle of the product, and stabilize welding quality while ramping up the welding speed.

Many clients praise the superior welding quality provided by welding robots, but what are the standards for evaluating the welding quality of these robots?

To answer this prevalent question, today I will elaborate on the various methods and techniques employed to assess the quality of welding performed by welding robots.

I. Observing the Weld Quality on the Surface of Robotically Welded Parts

1. Did you know? Robotic welders actually feature an intelligent welding system. They operate independently through offline programming in a computer, requiring only the setup of the robot’s movement path, torch posture, and welding parameters.

During the welding process, visual sensors intelligently identify the position and specifications of the weld seam, depositing suitable welding materials to ensure good seam fill.

2. After cooling, the next step for operators is to visually inspect the fill level of the weld seam. A well-formed weld seam is characterized by its surface being higher than that of the welded parts, featuring smooth and aesthetically pleasing weld ripples.

Welding defects such as weld tumors, cracks, burn-through, porosity, and spatter on the surface of the parts are absent.

II. Non-Destructive Testing of Robotic Welder Seams

Robotic welding seam flaw detection can perform penetrative inspections without damaging the welds. Various detection methods are available, and the appropriate one can be chosen based on the material of the welded parts and the specifications of the welds, which then determine the rework rate of the welds.

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1. Radiographic testing method: X and Y rays penetrate the welds, and defects within the welds are displayed as images on the radiographic film.

2. Ultrasonic testing method: Instantaneous electrical stimulation creates pulse vibrations. A coupling agent is applied to the surface of the weld, and the coupling medium forms ultrasonic waves in the metal. When these waves encounter a defect, they emit a reflection signal. This method works on the same principle as ultrasound examinations in medical facilities.

3. Magnetic testing method: Magnetic powder is sprinkled on the surface of the weld. The magnetic material reacts to defects. If a welding defect is detected, a magnetic leakage field appears.

Of course, besides the methods mentioned above, non-destructive testing methods for robotic welding seams also include liquid penetrant inspection, eddy current testing, and others. Here, I’ve only listed a few common testing methods; I hope they will be helpful.

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