![Page 1: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/1.jpg)
AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA
Matt Swanson, Eric Johnson, Alexander StoytchevIowa State University
John Deere
![Page 2: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/2.jpg)
Motivation Bad welds are expensive
Warranty claims Down time
Current quality assurance methods are time consuming Hand measuring weld parameters Procedure can take 1-2 hours for a single
weld
![Page 3: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/3.jpg)
Results of Bad Welds
![Page 4: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/4.jpg)
Some Weld Types
![Page 5: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/5.jpg)
This Work Focuses on T-fillet Welds
![Page 6: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/6.jpg)
Bad vs Good Welds
![Page 7: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/7.jpg)
Previous Approach
![Page 8: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/8.jpg)
Previous Approach
![Page 9: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/9.jpg)
Previous Approach
![Page 10: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/10.jpg)
Previous Approach
Dental Molding is applied Molding is cross sectioned
![Page 11: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/11.jpg)
Previous Approach
![Page 12: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/12.jpg)
Previous Approach
![Page 13: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/13.jpg)
Previous Approach
R
Theta
![Page 14: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/14.jpg)
Previous Approach The bending and the membrane
stress concentration factors of the weld are given by:
469.572. )(512.1 rtK b
t
469.37. )(388.1 rtK m
t
![Page 15: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/15.jpg)
Our Approach (1) Scan the Weld
Powder weld with reflective
material
Aramis Camera Extract high
resolution 3D point clouds 50 micron resolution
![Page 16: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/16.jpg)
Our Approach (2) Determine Geometry
Cluster Normals For every 3 neighboring points
(p,q,r)calculate vectors u and vu = q - p v = r - p K-means cluster on the plane
created fromthe cross product of u and v Fit Planes to Plate
Clusterscalculate plane from histogram of
green andblue clusters
![Page 17: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/17.jpg)
Our Approach (3) Extract Weld Parameters
Slice Weld ClusterSlice weld along contour of the
interesection between the weld and plane
Fit Circle to Weld Toe Fit R1 and R2 Extract interior
points Circle fit
![Page 18: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/18.jpg)
Results(Compare the two
Approaches)
![Page 19: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/19.jpg)
Results (Slice #7 on Weld #1)
![Page 20: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/20.jpg)
Results (Weld #1)
![Page 21: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/21.jpg)
Results (Weld #1)
2.2% difference
![Page 22: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/22.jpg)
Results (Weld #2)
1.9% difference
![Page 23: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/23.jpg)
Video
![Page 24: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/24.jpg)
ART Tracker
![Page 25: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/25.jpg)
ART Tracker
![Page 26: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/26.jpg)
Future Work Build a handheld device to scan
welds Couple a pico-projector with a web cam
Extend our software to scan entire assemblies and identify the welds on them automatically
Test under factory conditions
![Page 27: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/27.jpg)
Summary and Conclusions
![Page 28: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/28.jpg)
Questions?
![Page 29: AUTOMATED WELD INTEGRITY ANALYSIS USING 3D POINT DATA](https://reader036.vdocuments.us/reader036/viewer/2022062812/56816312550346895dd38af4/html5/thumbnails/29.jpg)