DOE OSTI2023
The conventional method of weld process monitoring is to monitor the process output electrical power close to the point of welding. Non-Intrusive Load Monitoring (NILM) describes the method of monitoring primary or utility electrical power into a welding process well away from the point of welding. The objective of this project was to determine if there is sufficient information within the welding process input power to understand process output power characteristics, and, if so, determine if there is sufficient resolution within the input electrical characteristics to infer some measures of weld quality. To understand the relationship between process input and output power, both input and output power were monitored for two welding processes (GMAW and GTAW) and two different power source types (inverter and SCR). Welds were made with and without intentional disturbances. The results showed that there is a strong correlation between input and output power and that the influence of process disturbances are evident within the input power. A simple method using input power only was devised and successfully demonstrated to discriminate between a weld made with no intentional disturbance (a nominal weld) from a weld made with an intentional disturbance (off-nominal weld). The primary conclusions of this work is that NILM of process input power is sensitive to process disturbances that could influence weld quality and that the approach warrants additional study.