arXiv:2508.04595cs.LG2025-08

用真实实验数据训练物理神经网络,实现铝点焊质量非破坏性快速评估。

Improved Training Strategies for Physics-Informed Neural Networks using Real Experimental Data in Aluminum Spot Welding

  • 渐进式引入实验损失,缓解优化冲突
  • 预测位移与熔核生长在实验误差范围内
  • 适合工业界快速质量控制场景

电阻点焊是汽车白车身制造中的主流连接工艺,焊点直径是关键质量指标,但其测量需破坏性测试,限制了高效质量控制。物理信息神经网络被用于从实验数据重构内部过程状态,实现铝点焊的模型化、非侵入式质量评估。主要挑战在于真实数据与物理约束间的优化冲突。为此,本文提出两种新训练策略:首先,通过衰减函数逐步引入动态位移和焊点直径的实验损失,避免优化冲突;其次,采用基于滚动窗口的自定义学习率调度与早停机制,防止因损失量级上升导致过早收敛。此外,引入条件更新的温度相关材料参数查表机制,在损失阈值后激活,确保温度物理合理性。采用轴对称二维模型精确模拟焊接过程并保持计算效率。为降低计算负担,先在一维条件下系统评估训练策略与接触模型。二维网络预测的动态位移与焊点增长均在实验置信区间内,支持从钢到铝焊接阶段的迁移,并展现出在工业应用中实现快速模型化质量控制的强大潜力。

原文摘要 · Abstract (English)

Resistance spot welding is the dominant joining process for the body-in-white in the automotive industry, where the weld nugget diameter is the key quality metric. Its measurement requires destructive testing, limiting the potential for efficient quality control. Physics-informed neural networks were investigated as a promising tool to reconstruct internal process states from experimental data, enabling model-based and non-invasive quality assessment in aluminum spot welding. A major challenge is the integration of real-world data into the network due to competing optimization objectives. To address this, we introduce two novel training strategies. First, experimental losses for dynamic displacement and nugget diameter are progressively included using a fading-in function to prevent excessive optimization conflicts. We also implement a custom learning rate scheduler and early stopping based on a rolling window to counteract premature reduction due to increased loss magnitudes. Second, we introduce a conditional update of temperature-dependent material parameters via a look-up table, activated only after a loss threshold is reached to ensure physically meaningful temperatures. An axially symmetric two-dimensional model was selected to represent the welding process accurately while maintaining computational efficiency. To reduce computational burden, the training strategies and model components were first systematically evaluated in one dimension, enabling controlled analysis of loss design and contact models. The two-dimensional network predicts dynamic displacement and nugget growth within the experimental confidence interval, supports transferring welding stages from steel to aluminum, and demonstrates strong potential for fast, model-based quality control in industrial applications.

物理信息网络点焊质量铝焊接非破坏检测

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