Online welding quality monitoring for large-size electrical contact high frequency induction brazing

• Integral value of electrical parameters is an indication of welding quality.
• Ideal integral value decreases with the increase of the average power output.
• Ideal integral value correlates to average energy output in a single pulse.
• Welding quality can be estimated by the limit deviation of integral value.

In the low voltage apparatus manufacturing industry, the welding quality of electrical contact directly determines the switching capacity, lifespan and reliability of electrical equipment. Currently, only a little research on online monitoring of large-size electrical contact high frequency induction brazing has been carried out. In this research, CJ400 electrical contact was used as samples to be welded in the way of pulse induction brazing. And the electrical parameters during the whole welding process were collected and integrated with the dual 32-bit ARM (Advanced RISC Machines) controller. The relationship between welding quality and integral value of electrical parameter was analyzed. The results showed that the deviation between the ideal integral value of electrical parameters and the actual integral value of electrical parameters could be identified an indication for welding quality.

Figure optionsDownload as PowerPoint slide