Integrated molten pool camera

Abstract

The utility model discloses an integrated molten pool camera, and belongs to the technical field of welding observation equipment. The device comprises an industrial camera, a light source control panel, a light source and an angle-adjustable mounting bracket, the illumination angle of the light source is adjusted through the mounting bracket; the light source comprises a laser for generating laser and a laser chip for controlling the laser to generate laser; the light source control board adopts a circuit board structure formed by stacking a plurality of layers of boards, and is welded with the control board in the industrial camera in a stacking manner; the light source works cooperatively with the industrial camera under the control of the light source control panel; the industrial camera converts collected optical signals into electric signals, and video images are obtained through collection. The integrated molten pool camera disclosed by the utility model solves the problem that real-time observation cannot be carried out by using a common camera under the conditions that intermittent strong light is generated in the welding process of arc welding, laser welding and the like, and the intermittent strong light is flicker, the light and shade difference is large and the change period is extremely short.

Description

Technical Field

[0001] This utility model relates to a real-time observation system for arc welding, specifically to a molten pool camera within the observation system, and belongs to the technical field of welding observation equipment. Background Technology

[0002] In the field of arc additive manufacturing, quality inspection during the welding process is crucial for the quality assessment of the final product. During arc additive manufacturing, the geometric features of the molten pool contain a wealth of information that reflects the welding quality. In the past, workers wearing welding masks would observe and record this information constantly. However, the working time of arc additive manufacturing can sometimes be tens or even hundreds of hours. This not only requires workers to take turns to maintain their positions, which consumes manpower, but also has the effect of long-term exposure to welding dust on the health of workers. Moreover, it can only be observed during the welding process and cannot be reviewed afterward.

[0003] To improve traditional observation methods, existing methods use cameras to acquire images of the weld pool, which contain rich welding quality information. Alternatively, visual sensors can be used to acquire images of the weld pool, providing real-time morphological information such as molten droplets, the weld pool, and the welding arc, thereby enabling real-time monitoring and evaluation of welding quality.

[0004] However, due to the limited payload of welding robots and the inherent mass of the welding torch, the lighter the camera and vision sensor, the wider the range of applicable environments. Therefore, weld pool cameras typically installed at the end of a robot or in welding carriages are designed to be as small and lightweight as possible. This requires reducing the size of the weld pool camera and the complexity of its installation and wiring to improve its adaptability to the installation and usage environment. Utility Model Content

[0005] The technical problem to be solved by this utility model is to overcome the defects of the prior art and provide an integrated molten pool camera.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is as follows:

[0007] An integrated molten pool camera includes an industrial camera, a camera lens with an adjustable distance from the industrial camera, a light source control board, a light source, and an adjustable-angle mounting bracket.

[0008] The light source is mounted on a mounting bracket, and the illumination angle of the light source can be adjusted by the mounting bracket.

[0009] The mounting bracket is positioned in front of the camera lens;

[0010] The light source control board adopts a multi-layer board stacked circuit board structure and is soldered together with the control board in the industrial camera in a stacked manner.

[0011] The light source works in conjunction with the industrial camera under the control of the light source control board;

[0012] The industrial camera converts the collected light signals into electrical signals to acquire video images.

[0013] Furthermore, the light source includes a laser for generating laser light and a laser chip for controlling the laser to generate laser light; the laser chip is packaged on a ceramic copper-clad substrate to form a thin-film plate light source.

[0014] Furthermore, the light source may be one or more; when there are multiple light sources, the multiple light sources are arranged around the lens of the industrial camera by means of a mounting bracket.

[0015] Furthermore, the captured video images are transmitted to the host computer for storage via a data cable.

[0016] Furthermore, it also includes a filter mounted on an industrial camera.

[0017] Furthermore, the industrial camera, camera lens, light source control board, light source, and mounting bracket are all housed within a single housing.

[0018] Furthermore, the outer casing is provided with a protective lens through which light can pass.

[0019] Furthermore, a temperature measuring camera is also installed inside the outer casing.

[0020] Furthermore, the housing is provided with at least one adjustment hole, and a lens mounting base is provided inside the housing corresponding to the position of the adjustment hole; the camera lens is supported and fixed by the lens mounting base, and the distance between the camera lens and the industrial camera is adjusted by the lens mounting base.

[0021] Furthermore, the inner wall of the outer casing is also provided with a wiring groove for arranging the power supply lines of the light source.

[0022] The beneficial effects achieved by this utility model are:

[0023] This invention discloses an integrated weld pool camera to address the problem of intermittent strong light generated during arc welding, laser welding, and other welding processes. This intermittent light, with its large brightness variations and extremely short cycles (on the μs level, with an arc welding cycle of approximately 14 μs), makes real-time observation of the weld pool impossible with ordinary cameras. The integrated camera allows for better observation of the weld pool video image. This integrated weld pool camera is lighter, smaller, and more integrated, avoiding complex wiring and offering greater adaptability to various installation and usage environments. Attached Figure Description

[0024] Figure 1This is a schematic diagram of the integrated melt pool camera structure in this embodiment;

[0025] Figure 2 yes Figure 1 A structural diagram of the hidden protective lens (the protective lens is not shown in the figure);

[0026] Figure 3 yes Figure 1 Schematic diagram of the internal structure of the outer shell (the outer shell and protective lens are not shown in the figure);

[0027] Figure 4 This is a schematic diagram of the integrated molten pool camera data control and transmission in this embodiment;

[0028] Figure 5 This is a flowchart of the video image acquisition method for the molten pool camera in this embodiment;

[0029] In the diagram, 1 is the outer casing, 11 is the adjustment hole, 12 is the wiring channel, 2 is the industrial camera, 21 is the control board, 3 is the camera lens, 31 is the lens mount, 4 is the filter, 5 is the light source control board, 6 is the light source, 7 is the mounting bracket, and 8 is the protective lens. Detailed Implementation

[0030] The present invention will be further described below with reference to the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and should not be used to limit the scope of protection of the present invention.

[0031] like Figure 1 , Figure 2 , Figure 3 and Figure 4 As shown, the integrated molten pool camera in this embodiment mainly includes an industrial camera 2, a camera lens 3, a lens mounting base 31, a filter 4, a light source control board 5, a light source 6, and a mounting bracket 7, all housed within the housing 1.

[0032] The light source 6 is mounted on a mounting bracket 7, which is positioned in front of the camera lens 3. The angle of the light source can be adjusted via the angle-adjustable mounting bracket 7, allowing the light source 6 to illuminate the center of the field of view of the industrial camera 2. The camera lens 3 is supported and fixed by a lens mount 31, which maintains a certain distance from the industrial camera 2. The lens mount 31 is a ring with threads on both its inner and outer circumferences. A filter 4 is positioned between the camera lens 3 and the industrial camera 2.

[0033] The front end of the housing 1 is equipped with a protective lens 8 that allows light to pass through. The protective lens 8 is used to protect the internal structure of the housing and prevent welding slag from damaging the industrial camera and camera lens during the welding process. The protective lens 8 can be replaced as needed.

[0034] The housing 1 is provided with at least one adjustment hole 11. The position of the adjustment hole 11 corresponds to the lens mount 31 of the camera lens 3 inside the housing 1, so that the distance between the camera lens 3 and the industrial camera 2 can be adjusted by adjusting the lens mount 31 outside the housing, and the clarity of the captured image can be adjusted by changing the distance.

[0035] The inner wall of the outer casing 1 is also provided with a wiring groove 12 for arranging the power supply line of the light source.

[0036] Light source 6 includes a laser for generating laser light and a laser chip for controlling the laser to generate laser light. There can be one or more light sources. The laser chip is packaged on a ceramic copper-clad substrate to form a thin-film plate light source. When there are multiple light sources, the multiple light sources are arranged around the camera lens by mounting brackets.

[0037] Ceramic-clad copper substrates are composed of a ceramic substrate and copper foil. Current packaging technologies primarily use all-ceramic substrates, which are expensive, brittle, easily damaged, and difficult to store and use. This solution, however, utilizes a ceramic-clad copper substrate, which offers excellent insulation properties, effectively isolating signal interference between circuit layers and improving circuit stability and reliability. Furthermore, its superior thermal conductivity allows for rapid heat dissipation, ensuring the normal operating temperature of electronic devices and extending product lifespan and performance. Additionally, it exhibits good high-temperature resistance and corrosion resistance, enabling it to withstand complex and harsh working environments and ensuring long-term stable circuit operation.

[0038] Multiple light sources 6, under the control of the light source control board 5, can work collaboratively with the industrial camera 2. Specifically, the light source control board drives multiple sets of laser chips to work in conjunction with the industrial camera, providing better illumination for the industrial camera. The light source control board 5 adopts a multi-layer board stacked circuit board structure, reducing the size of the light source control board. The light source control board 5 and the control board 21 in the structure of the industrial camera 2 are also soldered together in a stacked manner. Laser illumination is used, along with filters, to reduce the impact of arc light and dimness changes on camera image acquisition. Even under the influence of arc light, clear images of the molten pool can still be captured in real time. The molten pool images are saved and can be retrieved by technicians at any time for analysis of the molten pool morphology.

[0039] Lasers are a type of stimulated emission, which excites photons through continuous energy transitions. They have high luminous intensity and are monochromatic, with a spectral width generally within 1 to 10 nm. They have high color purity, stable wavelength (i.e., the center wavelength is not easily changed), good coherence, small divergence angle, and can maintain perpendicular illumination with almost constant illumination area even under long-distance irradiation.

[0040] In this embodiment, near-infrared light is selected. It has high penetration, can travel over longer distances, and shows almost no attenuation within a 350mm working distance. Furthermore, the irradiated area does not change significantly. It can concentrate the power of the electro-optical conversion to produce stronger light at a specific center wavelength. By using a filter, the impact of arc light variations on camera image acquisition can be reduced. In other embodiments, different laser bands, such as red light, can be selected depending on the application scenario.

[0041] The molten pool camera described in this invention only requires one data cable for communication with the host computer and one power cable for external connection. It has a simple structure, is easy to use, and avoids complicated wiring.

[0042] The molten pool camera of this invention can be made to be approximately 30*30*60 mm in size, which is almost the same size as or only slightly larger than that of a regular industrial camera. Therefore, it can be installed on the side of the welding torch and move with the torch without the need to predict the welding path. This makes the application scenarios more flexible and the use more convenient, truly realizing the functions and performance of a monitoring camera.

[0043] Industrial cameras convert light signals into electrical signals and transmit them to a host computer server via data cables for storage.

[0044] A point temperature camera can also be installed inside the casing to monitor the area temperature in real time.

[0045] Industrial cameras observe the state of the molten pool by capturing and storing images in real time. They can also simultaneously monitor the temperature of the area in real time through an internal point temperature measuring camera. This eliminates the need for workers in the field of arc additive manufacturing to take turns observing and recording, saving manpower, improving safety, and facilitating repeated observation of the molten pool state during the welding process after welding is completed.

[0046] The working process of the molten pool camera of this utility model for acquiring video images is as follows: Figure 5 As shown, it includes the following steps:

[0047] The mounting bracket can be adjusted to adjust the illumination angle of the light source mounted on it, so that the laser shines on the center of the field of view of the industrial camera.

[0048] The laser chip controls the laser to generate a single wavelength laser with a divergence angle of no more than 20°, so that the luminous intensity of the laser is greater than that of the electric arc light.

[0049] Adjust the exposure time of the industrial camera according to the brightness of the light source;

[0050] Narrow-band filters are used to filter out light other than the desired wavelength from the presented video image;

[0051] Industrial cameras convert light signals of a single wavelength into electrical signals to capture video images.

[0052] The captured video images are transmitted to the host computer for storage via a data cable.

[0053] The above description is only a preferred embodiment of the present utility model. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present utility model, and these improvements and modifications should also be considered within the protection scope of the present utility model.

Claims

1. An integrated molten pool camera, characterized in that, Includes an industrial camera, a camera lens with an adjustable distance from the industrial camera, a light source control board, a light source, and an adjustable mounting bracket; The light source is mounted on a mounting bracket, and the illumination angle of the light source can be adjusted by the mounting bracket. The mounting bracket is positioned in front of the camera lens; The light source control board adopts a multi-layer board stacked circuit board structure and is soldered together with the control board in the industrial camera in a stacked manner. The light source works in conjunction with the industrial camera under the control of the light source control board; The industrial camera converts the collected light signals into electrical signals to acquire video images.

2. The integrated molten pool camera according to claim 1, characterized in that, The light source includes a laser for generating laser light and a laser chip for controlling the laser to generate laser light; the laser chip is packaged on a ceramic copper-clad substrate to form a thin-film plate light source.

3. The integrated molten pool camera according to claim 1, characterized in that, The light source is one or more; when there are multiple light sources, the multiple light sources are arranged around the lens of the industrial camera by mounting brackets.

4. The integrated molten pool camera according to claim 1, characterized in that, The captured video images are transmitted to the host computer for storage via a data cable.

5. The integrated molten pool camera according to claim 1, characterized in that, It also includes a filter that is mounted on an industrial camera.

6. The integrated molten pool camera according to claim 1, characterized in that, The industrial camera, camera lens, light source control board, light source, and mounting bracket are all housed within a single housing.

7. The integrated molten pool camera according to claim 6, characterized in that, The outer casing is equipped with a protective lens through which light can pass.

8. The integrated molten pool camera according to claim 6, characterized in that, A point temperature camera is also installed inside the outer casing.

9. The integrated molten pool camera according to claim 6, characterized in that, The housing has at least one adjustment hole, and a lens mounting base is provided inside the housing corresponding to the position of the adjustment hole; the camera lens is supported and fixed by the lens mounting base, and the distance between the camera lens and the industrial camera is adjusted by the lens mounting base.

10. The integrated molten pool camera according to claim 6, characterized in that, The inner wall of the outer casing is also provided with a cable tray for arranging the power supply line of the light source.

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