Real-Time Weld Quality Prediction in Automated Stud Welding: A Data-Driven Approach

Beatriz Coutinho, Bruno Santos, Rita Gomes Mendes, Gil Gonçalves, Vítor H. Pinto

2025

Abstract

Drawn arc stud welding is extensively used in automotive assembly lines for attaching components to vehicle bodies. In these automated processes, low-quality welds can compromise structural integrity and cause production delays due to rework and maintenance. This paper describes the initial development stage of an artificial intelligence (AI)-based system for real-time weld quality prediction in automated stud welding. The focus of this first phase is on implementing sensorisation, developing a data acquisition system, and constructing a dataset that captures the most relevant process variables characterizing the welding process. A Flask-based application was developed to facilitate data collection, incorporating an automatic character recognition algorithm to extract parameters directly from the control unit display. Initial welding experiments produced a dataset of approximately 200 samples, with preliminary data analysis validating expected parameter trends. The results confirm the system’s capability to effectively capture relevant data, forming the basis for future development of a predictive model aimed at enhancing weld quality monitoring and minimizing assembly line interruptions.

Paper Citation

in Harvard Style

Coutinho B., Santos B., Mendes R., Gonçalves G. and Pinto V. (2025). Real-Time Weld Quality Prediction in Automated Stud Welding: A Data-Driven Approach. In Proceedings of the 22nd International Conference on Informatics in Control, Automation and Robotics - Volume 1: ICINCO; ISBN 978-989-758-770-2, SciTePress, pages 251-258. DOI: 10.5220/0013714100003982

in Bibtex Style

@conference{icinco25,
author={Beatriz Coutinho and Bruno Santos and Rita Mendes and Gil Gonçalves and Vítor Pinto},
title={Real-Time Weld Quality Prediction in Automated Stud Welding: A Data-Driven Approach},
booktitle={Proceedings of the 22nd International Conference on Informatics in Control, Automation and Robotics - Volume 1: ICINCO},
year={2025},
pages={251-258},
publisher={SciTePress},
organization={INSTICC},
doi={10.5220/0013714100003982},
isbn={978-989-758-770-2},
}

in EndNote Style

TY - CONF

JO - Proceedings of the 22nd International Conference on Informatics in Control, Automation and Robotics - Volume 1: ICINCO
TI - Real-Time Weld Quality Prediction in Automated Stud Welding: A Data-Driven Approach
SN - 978-989-758-770-2
AU - Coutinho B.
AU - Santos B.
AU - Mendes R.
AU - Gonçalves G.
AU - Pinto V.
PY - 2025
SP - 251
EP - 258
DO - 10.5220/0013714100003982
PB - SciTePress