Weld Cell Repeatability Studies - Origin - The 'drilled hole panel' Methodology

S

Sturmkind

#1
Hi, all!
I was wondering if anyone knows of the origins of formally testing for weld cell repeatability using the 'drilled hole panel' methodology wherein:
1) Parts are laid upon the fixture and holes, say 5mm diameter, are drilled in significant points in each of 3 axis.

2) Clamps are then activiated and any 'winking' or obstructions of the drilled holes are noted and each drilled hole is checked with a 4.5mm pin. If 4.5mm pin passes, then the mislocation is not greater than 0.25mm radially.
-Step 2 is repeated 5 times. If all pass pin check, this phase is OK. If not, stop, check for root cause, clear, and repeat.

3) Once step 2 passes, clamp and weld parts. Check for winking condition and conduct pin check again. If pass, study is done.
-If fail, check clamp pressure, sequence, datum pad to part fit (datums may be too large or mis-placed for parts), weld pressure and weld sequence.

My company deployed this method and it works very well.

The reason for the question is that I suspect that the best weld cell builders have used this methodolgy for decades and someone or some company finally decided to codify it into written instructions / procedures.

Let me know!
 
Elsmar Forum Sponsor

Marc

Fully vaccinated are you?
Leader
#2
A quick "Bump". If anyone has any experience in this (or thoughts about), my Thanks in advance for helping!

I have seen this done but I have no idea what the origin is.
 
J

JaxQC

#3
Not aware of the history of it but I do like the logic and thinking behind it. Basically if your clamps are not coming in timed correct, not the correct sequence, mismatched pressures etc it would show up. Only thing I’d also throw in is rotation or indexing if it is involved. That way you also take into consideration if there is enough pressure and bracing for the weight involved to take shifting of the material into consideration.
 
S

Sturmkind

#4
Thanks, JaxQC.

Actually, the cell we did this on does have a rotary indexing function and you are quite correct. We found that the largest influence on dimensional stability was distortion as a result of the sequence of welds (after we discovered that a couple of fixture details had to be 'cleared' to allow the parts to sit properly).

Changing the sequence cut our dimensional profile variability in half.
 
Thread starter Similar threads Forum Replies Date
R Robotic weld cell - maintenance issues - expertise needed Manufacturing and Related Processes 0
B Facility Weld Engineer Requirements Manufacturing and Related Processes 5
M Spot Weld Nugget - MSA Gage R&R Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 2
M Weld Symbol--Bubble Drawings for FAI Document Control Systems, Procedures, Forms and Templates 4
R Weld Penetration Standards and Requirements Manufacturing and Related Processes 2
B CQI-15 Weld Inspector vision reviewed annually Various Other Specifications, Standards, and related Requirements 5
H FCA projection weld nut IATF 16949 - Automotive Quality Systems Standard 11
Z CQI-15 Welding System Assessment - Robotic Ultrasonic Foam onto Plastic "Weld" applicable? Various Other Specifications, Standards, and related Requirements 3
K Spot weld - Peel test failure Manufacturing and Related Processes 3
E European Weld Callouts - Confused with the "/C" and the "a2" portions Various Other Specifications, Standards, and related Requirements 7
B Weld Validation on Titanium Parts ISO 13485:2016 - Medical Device Quality Management Systems 1
V Tolerance achievable for Sheet Metal Part with some weld - 0.4mm TP Manufacturing and Related Processes 5
V Rust and Paint adhesion with new Weld Nut Supplier Manufacturing and Related Processes 5
R How to Inspect the Weld Strength of High Pressure Vessel & Oil Pipe Line Inspection, Prints (Drawings), Testing, Sampling and Related Topics 2
F Welder Recertification to AWS 17.1 Groove Weld AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 9
M Weld Stud Length Poka Yoke Nonconformance and Corrective Action 3
5 Visual Weld Inspection Report - Example needed Manufacturing and Related Processes 3
Fender1 Controlling Documents and Records in a Custom Weld/Fabrication Company Document Control Systems, Procedures, Forms and Templates 10
B Laser Weld Strength - Laser Welding Medical Instruments Reliability Analysis - Predictions, Testing and Standards 8
J Weld Current Monitor Calibration Laboratory in North America General Measurement Device and Calibration Topics 6
L AWS Certified Weld Inspector (CWI) Requirement Question Manufacturing and Related Processes 16
K Inspecting a Length of Weld - High Reject Rates Manufacturing and Related Processes 7
hogheavenfarm Does anyone know of a calibrated Fillet weld gage? General Measurement Device and Calibration Topics 12
automoto Visual Inspection of a Weld - MSA (Measurement System Analysis) Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 4
D Laser Weld Operational Qualification ISO 13485:2016 - Medical Device Quality Management Systems 3
C ID (Inside Diameter) Threads Shrinking due to Heat Treatment and Weld Manufacturing and Related Processes 11
I Weld Repair and Nonconformance reporting Nonconformance and Corrective Action 3
A Weld Penetration on GM 6122M Various Other Specifications, Standards, and related Requirements 2
Domoreto Spot Welding aust. 304 Stainless Steel - Report on Contrition of Weld Manufacturing and Related Processes 1
L Eliminating a Recurring Problem of Missing Weld Nuts/Fasteners Manufacturing and Related Processes 27
L How to Avoid Missed Welds - Job shop and weld several small quantity jobs Manufacturing and Related Processes 11
bobdoering Determining a Good Variable for Small Scale Weld Integrity Capability Evaluation Capability, Accuracy and Stability - Processes, Machines, etc. 7
P Process vs. Product on Control Plan - Weld a nut attachment on the subassembly FMEA and Control Plans 3
J Pull test standard? Wires coming off the electrodes at the weld ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 5
R Visual Weld inspection training Inspection, Prints (Drawings), Testing, Sampling and Related Topics 1
J Spot Weld Current Tester Calibration Supplier needed - 5000 to 20000 A range General Measurement Device and Calibration Topics 2
B Weld Specifications - EU vs. AWS - Are AWS procedures recognized by the EU? Manufacturing and Related Processes 2
M Cost Estimating Spreadsheet for a CNC Machine & Weld Shop Manufacturing and Related Processes 8
A Toyota Weld Specification TSH5603G needed Customer and Company Specific Requirements 6
3 General MIG Weld Workmanship Standard or Procedure Manufacturing and Related Processes 2
F Weld Symbol Interpretation Training Resources - Video and/or overheads, etc. Manufacturing and Related Processes 4
L Weld Nut Thread Quality - Thread chaser for a M8-1.25 internal thread? Manufacturing and Related Processes 3
J Weld Penetration - ANSI/AWS D14.3-94 - Qualifying welding procedures Various Other Specifications, Standards, and related Requirements 8
D Calibration Standard N24: PFM NO 1841 - Ultrasonic Inspection of Resistance Spot Weld Document Control Systems, Procedures, Forms and Templates 1
D Weld Stepper Validation in production weld-cells Preventive Action and Continuous Improvement 6
G Is a Weld Destruct Test Effective - Have any of you ever used this test? Inspection, Prints (Drawings), Testing, Sampling and Related Topics 13
R Gage R&R for a Destructive Test - Weld Breakout Test Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 3
K Weld Inspection of Assemblies - Agricultural spreaders manufacturer Inspection, Prints (Drawings), Testing, Sampling and Related Topics 11
G Destructive Testing MSA - Weld Bond Pull - Both destructive and non destructive Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 10
L Single-cell lithium ion battery regulations IEC 60601 - Medical Electrical Equipment Safety Standards Series 0

Similar threads

Top Bottom