Wear inspection of spot-welding electrode caps
The welding gun enters the inspection pocket and the opposing electrode caps are imaged. Diameter and contour are compared in backlit silhouette and ring-lit end views; the wear result is reported to the tip-change station.
Tip diameter, contour difference and decision appear on the display; NG is reported to the tip-change station. The stack light shows the result as the welding gun leaves the inspection pocket.
- 01 Inspection pocket
- 02 Two views
- 03 Contour
- 04 Maintenance decision
The open gun arrives at the imaging position.
- Contact diameter
- —
- Contour difference
- —
Scenes are illustrative simulations; they are not customer references or performance guarantees.
Need
Reflections and surface deposits on a copper cap obscure the contact-face boundary. Wear can enlarge the diameter and also change the tip contour asymmetrically.
Solution approach
A fixed side camera captures the tip profile against a backlight, while a second camera looking up at an angle images the contact face with a ring light around its lens. Silhouette edges and end contour are evaluated together; both images appear on the operator display with gauging lines.
Process steps
- 01
Inspection pocket
The open gun arrives at the imaging position.
- 02
Two views
Side silhouette and end-face images are acquired.
- 03
Contour
Contact diameter and tip contour are compared.
- 04
Maintenance decision
The wear result is reported to the tip-change station.
Related applications
Let us assess your application together
We test your sample in our laboratory and report on resolution, optics and lighting selection.