Expulsion Identification in Resistance Spot Welding by Electrode Force Sensing Based on Wavelet Decomposition with Multi-Indexes and BP Neural Networks

Expulsion identification is of significance for welding quality assessment and control in resistance spot welding. In order to improve the identification accuracy, a novel wavelet decomposition and Back Propagation (BP) neural networks with the peak-to-peak amplitude and the kurtosis index were proposed to identify the expulsion from electrode force sensing signals. The rapid step impulse and resultant damping vibration of electrode force was determined as a robust indication of expulsion, and this feature was extracted from the electrode force waveform by seven-layer wavelet decomposition with Daubechies5 wavelets. Then, the energy distribution proportion of the decomposed detail signals were calculated, and the highest-energy one was selected as the target signal. Two statistical indexes were introduced in this paper to measure the target signal in overall situation and volatility. The bigger the peak-to-peak amplitude is, the more violent the fluctuation is. Moreover, the higher the kurtosis index is, the stronger the impact is, and the lower the dispersion degree of the data is. Experimental analysis showed that neither the peak-to-peak amplitude nor the kurtosis index could accurately judge the expulsion defect individually, because of the early signal fluctuation, likely affected by the work-piece clamping, work-piece clearance, or the oxide film thickness. Therefore, the BP neural networks were introduced to identify the expulsion defects, which is a mature and stable non-linear pattern recognition method. Testing experiments presented good results with the trained networks and improved the evaluable accuracy effectively in the quality assessment of the resistance spot welding.