Linha de solda ponto robotizada inspecionada em tempo real por Sistema Spot FusionAutomatic Inspectionofspot welding100%is now a reality

Spot Fusion – Spot Weld Inspection

Technology Description

Spot Fusion is a technology developed for 100% inspection of spot welds. It achieves this by analyzing the electrical signatures generated during the manufacturing process and applying artificial intelligence to ensure maximum reliability and precision.

Spot Fusion is unique: it analyzes weld integrity using only electrical data.

Poorly Executed Weld
(Failed chisel test)

Cross section of a poorly executed spot weld with no visible nugget

Well-Executed
Weld

Cross section of a correctly executed spot weld with full nugget penetration

Good Weld, but with
Severe Parameters

Cross section of an acceptable spot weld with severe electrode indentation

Optionally, vision modules can be installed to identify cosmetic defects.

Displaced

Cosmetic defect detected on the spot weld surface by the vision module

Edge

Spot weld placed too close to the sheet edge

Burrs

Crater shaped cosmetic defect on the spot weld surface

Pierced

Pit shaped cosmetic defect on the spot weld surface

Missing

Same spot weld surface with no cosmetic defect present

With our applied technology, we ensure 100% quality inspection of spot welds, significantly reducing or even eliminating the need for manual inspection. Spot Fusion uses artificial intelligence to monitor the electrical signals of the welding process in real time, automatically identifying potential defects such as cold, missing, or out-of-specification welds. This solution enhances the reliability of the production process, reduces operational costs, and provides complete traceability of all welds performed.

Spot Fusion inspection screen showing weld results in real time
Spot Fusion screen with the electrical signature of the weld

Spot Fusion on Production Line

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Automotive plant with Strokmatic inspection on the production line
1

Vision King – Coiled Steel and Blanks:

Detects metallurgical defects while the decoils progrides allowing automation to cut defect free blanks.

2

Vision King – Metal Stamping

Detects defects in class A surface right after press operation.

3

Spot Fusion:

Detects weld defects using weld controller data, it can be paired with machine vision to inspect weld aesthetics.

4

Vision King – Laser Brazing Inspection

Visual inspection of Laser Brazing process allowing immediate trobleshooting.

5

Vision King – Adhesive and Sealant

Secure and imediate inspection system that allows operators only dadicate on fixing defects.

6

Vision King – E-coat and Primer

Detects contaminants and defects in e-coated or primed surface allowing operation to focus in fixes before advancing in the production process.

7

Vision King – Base Coat and Varnish

System deditated to inspect for defect on painted surface.

8

Vision King – Final Assembly

Inspects defects in real-time such as missing parts and misalignments under the car.

Technologies and Techniques Used in Inspection

Cameras and
Sensors

Image
Processing

Artificial
Intelligence

Real-Time
Systems

Advantages

  • 100% automated inspection of spot welds.

  • High precision and consistency in real-time defect detection.

  • High operational speed, matching the production line pace without impacting cycle time.

  • Immediate identification of cold, incomplete, missing, or off-standard welds.

  • Reduction or elimination of manual inspection, optimizing resources and reducing human errors.

  • Increased safety and ergonomics, minimizing repetitive efforts and exposure to risks.

  • Full traceability of each weld performed, ensuring complete process control.

  • Standardization of quality and increased production efficiency.

  • Contribution to Industry 4.0, integrating smart technology into the manufacturing process.

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