Weld Planning

< Principle > To find the optimal process parameter settings for running a stable welding production to obtain consistent weld results.

< Problem > Each factory has its own material suppliers and machine builders, where all welds need individualized process settings.

< Solution > Get optimized process parameter settings for each weld combination by weld planning with fully automated simulations.

SORPAS 2D planning diagram - from SORPAS calulated welding force, current and time to the welding machine control

Excel batch planning

This function for Excel Batch Simulation can provide solutions for optimizing and planning of welding process parameters by directly reading input data from Excel datasheet files. Then it automatically makes simulation files and runs all simulations and optimizations. SORPAS puts all optimization results back to the Excel datasheet file. This will save a lot of time for the users to prepare simulations and drastically increase the productivity!

With this function, the engineers can maximize the benefits of simulations and optimizations, and substantially reduce the number of physical tests. Moreover, they can improve the weld quality and production stability with the support of massive and fast simulations and optimizations.

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Intelligent weld planning

One of the mostly-used functions in SORPAS® 2D is the Intelligent Weld Planning for predicting the Optimal Weld Schedule (weld current, force, weld and hold time).

According to the user-defined Weld Task Description (WTD) with information of the sheets, electrodes, type of welding machine, and the desired weld quality, SORPAS® will automatically optimize and find the optimal weld current, force, weld time, and hold time.

The splash (expulsion) limit is predicted. Thereby SORPAS® predicts the welding process window between the required minimum weld nugget size and the splash (expulsion) limit.

The Weld Planning Report will be finally produced with the below information.

  • WTD information – sheets, electrodes, and weld machine
  • Predicted optimal Weld Schedule Specifications (WSS) – the welding process window with optimal weld current, force, weld time, and hold time
  • Weld Quality Results by the optimal welding process parameters.
weld planning example from SORPAS

SORPAS® Weld Planning Procedure

The SORPAS® Weld Planning works in the following procedure:

  • WTD – Weld Task Description
  • User Preferences
  • Run Weld Planning to predict Optimal Welding Parameters
  • Weld Planning Report with WSS – Weld Schedule Specifications

1) WTD – Weld Task Description is to define the weld task with specifications of sheets, electrodes, type of welding machine, and desired weld quality, see the figure to the right.

2) User Preferences are for user preferred planning strategy. SORPAS® will always optimize the weld current, but users have the freedom to choose their own preferred values for the weld force, weld time, or the number of pulses. You can either give a specific value or simply let SORPAS® fully optimize.

3) Run Weld Planning. After defining the Weld Task and User Preferences, you can start the Weld Planning. SORPAS® will then automatically run all the optimization procedures to first determine the optimal weld force and weld time, then to predict the welding process window and the splash (expulsion) limit, and finally to optimize the weld current and the hold time.

4) Weld Planning Report with WSS – the Optimal Weld Schedule Specifications is the results of the Weld Planning, which includes the given WTD, the predicted optimal welding process parameters (weld current, weld force, weld time and hold time), and the welding process window, as well as the weld quality results predicted with the optimal welding process parameters.

During the Weld Planning, all simulations and optimizations are done with only the same one data file. This substantially reduces the computation time and the use of hard disk space compared to the Weld Growth Curves and Weldability lobes.

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