Condition based maintenance of the two-beam laser welding in high volume manufacturing of piezoelectric pressure sensor

Kenda, Miha (author), Klobčar, Damjan (author), Bračun, Drago (author)

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.

• Language: English
• Keywords: two-beam laser welding, deterioration, condition-based maintenance, monitoring, expert knowledge
• Work type: Article
• Typology: 1.01 - Original Scientific Article
• Organization: FS - Faculty of Mechanical Engineering
• Publication status: Published
• Publication version: Version of Record
• Year: 2021
• Number of pages: Str. 117-126
• Numbering: Vol. 59
• PID: 20.500.12556/RUL-138454
• UDC: 621.791.72(045)
• ISSN on article: 0278-6125
• DOI: 10.1016/j.jmsy.2021.02.007
• COBISS.SI-ID: 52913667
• Publication date in RUL: 21.07.2022

Record is a part of a journal

• Title: Journal of manufacturing systems
• Shortened title: J. manuf. syst.
• Publisher: Elsevier, Society of Manufacturing Engineers
• ISSN: 0278-6125
• COBISS.SI-ID: 574226

Licences

• License: CC BY-NC-ND 4.0, Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International
• Link: http://creativecommons.org/licenses/by-nc-nd/4.0/
• Description: The most restrictive Creative Commons license. This only allows people to download and share the work for no commercial gain and for no other purposes.

Secondary language

• Language: Slovenian
• Keywords: dvožarkovno lasersko varjenje, degradacija, vzdrževanje na osnovi stanja sistema, nadzor, ekspertno znanje

Projects

• Funder: Other - Other funder or multiple funders
• Funding programme: Hidria Holding d.o.o.

• Funder: ARRS - Slovenian Research Agency
• Project number: P2-0270
• Name: Proizvodni sistemi, laserske tehnologije in spajanje materialov