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Condition based maintenance of the two-beam laser welding in high volume manufacturing of piezoelectric pressure sensor
Journal of Manufacturing Systems ( IF 12.1 ) Pub Date : 2021-02-20 , DOI: 10.1016/j.jmsy.2021.02.007
Miha Kenda , Damjan Klobčar , Drago Bračun

Two-beam laser welding (TBLW) is an advanced process for precise, low distortion joining of cylindrical miniature parts. The process is composed of a laser source, optics and various actuators, which form a sophisticated system for control and maintenance in high volume manufacturing. A well-established method for identifying welding defects and ensuring welding quality is the monitoring of plasma light emission in TBLW. Although such monitoring systems can detect a change in process status, they are not able to diagnose the nature of the fault. The main challenge in this research was to extend the use of quality-based monitoring systems to measure additional deterioration-related parameters and to estimate system deterioration from them by using expert knowledge.

This paper shows a novel condition-based maintenance (CBM) for the TBLW system, which performs condition identification using online monitoring of plasma light emission in combination with offline inspection of the seam macrographs. A combination of quality parameters derived from seam macrographs of defective parts is used to identify process deterioration, such as contamination of the optics, misalignment of the optomechanical system, or reduced laser power. The information obtained is used to make predefined process adjustments based on expert domain knowledge. The implementation of the developed CBM in high volume manufacturing of piezoelectric pressure sensors resulted in more predictable TBLW by reducing system failures as well as shorter diagnosis times.



中文翻译:

压电压力传感器批量生产中基于两束激光焊接的状态维护

两束激光焊接(TBLW)是一种先进的工艺,用于精确,低变形地连接圆柱形微型零件。该过程由激光源,光学器件和各种执行器组成,形成了用于大批量生产中控制和维护的精密系统。一种用于确定焊接缺陷并确保焊接质量的成熟方法是监视TBLW中的等离子辐射。尽管此类监视系统可以检测过程状态的变化,但它们无法诊断故障的性质。这项研究的主要挑战是扩展基于质量的监视系统的使用,以测量其他与劣化相关的参数,并使用专家知识从中评估系统的劣化。

本文展示了一种用于TBLW系统的新型基于状态的维护(CBM),该系统使用在线监测等离子光并结合对接缝宏观图进行离线检查来执行状态识别。从缺陷零件的接缝宏观图得出的质量参数的组合用于识别过程恶化,例如光学器件的污染,光机械系统的未对准或降低的激光功率。所获得的信息用于基于专家领域的知识进行预定义的过程调整。在压电压力传感器的大批量生产中,开发的CBM的实施通过减少系统故障以及缩短诊断时间,使TBLW更具可预测性。

更新日期:2021-02-21
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