A 3D molten pool real-time imaging device

Abstract

The application relates to a 3D molten pool real-time imaging device, belonging to the technical field of welding process monitoring, which comprises a shell, the shell being provided with an image acquisition module, a splitting optical element and light sources; the splitting optical element is used for splitting the light of a measured molten pool area into two left and right paths; the image acquisition module is used for acquiring the light signals after splitting by the splitting optical element and forming left and right view images; the light sources are at least provided in pairs, and the light sources in the same pair are symmetrically arranged about the symmetry axis of the splitting optical element. The application has the effect of realizing single-camera double-view imaging, improving light uniformity, and thus improving the brightness balance of left and right views and the imaging quality.

Description

Technical Field

[0001] This application relates to the field of welding process monitoring technology, and in particular to a 3D molten pool real-time imaging device. Background Technology

[0002] In additive manufacturing, the geometry of the molten pool (including width, height, and surface flatness) directly determines the quality of the formed layer. To achieve real-time control of the forming quality, it is usually necessary to perform online 3D imaging of the molten pool surface to obtain information on the three-dimensional morphology of the molten pool.

[0003] Existing molten pool monitoring systems mostly employ the principle of binocular stereo vision, using two parallel cameras to acquire images of the molten pool from different angles, and then reconstructing the molten pool in three dimensions through image matching and triangulation. However, this type of system has the following problems: dual cameras require strict calibration, are prone to inaccuracy under the high temperature and vibration environment of the welding site, and are cumbersome to maintain. Secondly, the cost of two high frame rate camera systems doubles, and the system is bulky, making it difficult to integrate into the space-constrained end effector of welding robots. It can only be fixedly installed in the working environment, unable to move flexibly with the robot end effector, cannot fully utilize all pixels to present the molten pool image, and is prone to image obstruction when the robot moves.

[0004] To address the aforementioned issues, existing solutions have attempted to employ a single camera combined with a beam splitter or mirror array to achieve the effect of acquiring two images from different perspectives with a single camera (e.g., the technical solution disclosed in the invention patent publication CN114383543A, entitled "Single CCD Dual-Prism Binocular Stereo Vision Sensor"), thereby partially replacing traditional dual-camera systems. However, existing solutions typically focus only on the implementation of the image splitting structure, lacking optimized design for illumination uniformity, image brightness consistency, and overall device integration. This can easily lead to significant brightness differences between the left and right views, making it difficult to extract molten pool boundary features and affecting the accuracy of subsequent stereo matching and 3D reconstruction. Utility Model Content

[0005] In order to improve illumination uniformity in single-camera dual-view imaging, thereby improving brightness balance and imaging quality in the left and right views, this application provides a 3D molten pool real-time imaging device.

[0006] The 3D molten pool real-time imaging device provided in this application adopts the following technical solution: A 3D molten pool real-time imaging device includes a housing, on which an image acquisition module, a splitting optical element, and a light source are disposed; The image-splitting optical element is used to split the light from the measured molten pool area into left and right paths; The image acquisition module is used to acquire the light signal after it has been imaged by the image-splitting optical element and form left and right view images; The light source is provided in at least one pair, and the light sources in the same pair are symmetrically arranged about the axis of symmetry of the image splitting optical element.

[0007] By adopting the above technical solution, the light sources are set in pairs and arranged symmetrically about the axis of symmetry of the splitting optical element, so that the molten pool area can obtain a balanced illumination intensity from left to right. Thus, when a single camera performs dual-view imaging, the brightness difference between the left and right views is significantly reduced, ensuring the consistency and reliability of the two images in the feature matching process. This device can be directly installed on the end effector of a welding robot, enabling the image acquisition module, split optical element and light source to move synchronously with the movement of the welding robot, thereby maintaining a fixed imaging angle and stable illumination position during welding or additive manufacturing, which is more conducive to improving imaging quality.

[0008] Optionally, the housing is further provided with a protective lens, which covers the light-emitting area of ​​the image-splitting optical element and the light source. The housing includes a base, a top cover, a mounting part, a first fixing member, and a second fixing member. The base and the top cover form an internal space for accommodating the image acquisition module; The mounting portion is used to accommodate the image-splitting optical element; The first fixing member is used to fix the image splitting optical element; The second fastener is located at the front end of the base and is used to install the protective lens; It also includes a positioning part, the image acquisition module is installed in the positioning part, and when the first fixing member fixes the image splitting optical element, the optical axis of the image acquisition module is coaxial with the symmetry axis of the image splitting optical element.

[0009] By adopting the above technical solution, the image acquisition module can be fixed to the base during installation. The image splitting optical element is securely installed in the housing through the mounting part and the first fixing component. Then, a protective lens is installed through the second fixing component to protect the light source and the image splitting optical element. The overall assembly process is simplified and installation is convenient. Furthermore, it can achieve direct integration with existing cameras or optical components, has strong versatility and adaptability, and facilitates the expansion of applications for different models of equipment.

[0010] Optionally, the upper cover is a cover structure, the mounting part includes an optical element positioning groove opened at the front end of the upper cover, the first fixing member includes a first pressing frame, the first pressing frame is connected to the front end of the upper cover, and the first pressing frame presses the image splitting optical element. The second fastener includes a protective mirror mounting frame and a second clamping frame. The protective mirror mounting frame is connected to the front end of the upper cover, and the first clamping frame is located between the protective mirror mounting frame and the upper cover. The second clamping frame is connected to the protective lens mounting frame, and the two together clamp the protective lens. The width of the protective mirror mounting frame is greater than the width of the upper cover, and the light source is mounted on the upper cover; The positioning part includes a first connecting hole on the base plate. The image acquisition module is fixed on the positioning plate through the first connecting hole. When the first clamping frame clamps the image splitting optical element, the optical axis of the image acquisition module is coaxial with the axis of symmetry of the image splitting optical element.

[0011] By adopting the above technical solution, a specific integration scheme for an image acquisition module, a splitting optical element, and a light source is provided. During installation, the image acquisition module is first installed on the base plate, and the top cover is placed on the base to cover the image acquisition module. Then, the splitting optical element is installed in the optical element positioning groove. Next, the first clamping frame is bolted to the top cover to press the splitting optical element, thereby fixing the splitting optical element. Subsequently, the light source is bolted to both sides of the housing. Finally, the protective lens is installed between the protective lens mounting frame and the second clamping frame. The protective lens mounting frame and the second clamping frame are then connected to the top cover to complete the integrated assembly.

[0012] The design of the protective mirror mounting frame being wider than the top cover allows more light sources to be placed on both sides of the top cover, providing a more complete and symmetrical illumination range.

[0013] Optionally, a light group power supply module is installed on the top of the cover, the light source is connected to the light group power supply module, a protective cover is connected to the cover, the protective cover covers the light group power supply module, a first wiring port is opened at the end of the protective cover away from the front end of the cover, and a second wiring port is opened at the end of the base away from the front end of the cover.

[0014] By adopting the above technical solution, an installation method for a light source power supply module is provided. This wiring method is convenient to install and simple to connect. The cover can be opened independently for maintenance and replacement of the light source. The protective cover can protect the power supply module and can also position and limit the wiring after it is closed to prevent the connection from becoming loose. The first and second connection ports allow the power supply lines for the light source and the image acquisition device to be led out separately, facilitating electrical connection with external control modules or independent power supplies. They are highly versatile and adaptable, and are especially suitable for the modular design requirements of the initial prototype and feasibility verification stages of the device.

[0015] Optionally, support brackets are connected to both sides of the top cover, and the light source is installed on both sides of the support brackets and the front end of the top cover.

[0016] By adopting the above technical solution, light sources are installed on both sides of the support bracket and the front end of the top cover, making the layout of the light sources more flexible. The number of light sources and the illumination angle can be adjusted according to different application scenarios, thereby achieving more comprehensive illumination coverage of the molten pool area.

[0017] Optionally, the protective cover has an annular groove, and the second clamping frame and the protective mirror mounting frame are clamped together in the annular groove.

[0018] By adopting the above technical solution, the second clamping frame and the protective mirror mounting frame are clamped together in the annular groove, so that the extended parts of the two after assembly are limited and constrained by the annular groove, which enables the protective cover to tighten the second clamping frame and the protective mirror mounting frame, and in turn enables the protective mirror mounting frame to press the first clamping frame, thereby improving the overall assembly stability.

[0019] Optionally, the base is a box structure with an open top, and both sides of the base are provided with protrusions, which together with the inner wall of the base form an insertion groove. The mounting part includes an optical element mounting base, which is inserted into the insertion slot. The image splitting optical element is installed in the optical element mounting base. The first fixing member includes a first fixing frame, which is installed on the optical element mounting base. The first fixing frame cooperates with the optical element mounting base to press the image splitting optical element. The light source is mounted on both sides of the optical element mounting base; The second fixing component includes a second fixing frame. A protective lens positioning groove is provided at the front end of the base. The second fixing frame is connected to the front end of the base. The second fixing frame cooperates with the base to press the protective lens. The positioning part includes a second connecting hole on the base plate. The image acquisition module is fixed on the positioning plate through the second connecting hole. When the first fixing frame presses the image splitting optical element, the optical axis of the image acquisition module is coaxial with the axis of symmetry of the image splitting optical element.

[0020] By adopting the above technical solution, another specific integration scheme for the image acquisition module, the image splitting optical element, and the light source is provided. During installation, the image acquisition module is first installed on the base, then the image splitting optical element is installed on the optical element mounting bracket, followed by the light source. The optical element mounting bracket is then inserted into the insertion slot, ensuring the first fixing frame is firmly against the image splitting optical element. Next, the protective lens is installed in the protective lens positioning slot, and the second fixing frame is bolted on to press the protective lens positioning slot. Finally, the top cover is placed on the base to complete the installation. This installation method allows the light source and the image splitting optical element to be completely housed within the space enclosed by the top cover and the base, resulting in a more compact structure and stronger sealing.

[0021] Optionally, a control board is installed inside the housing, and a plug is installed on the housing. The image acquisition module, the image splitting optical element, and the light source are all electrically connected to the control board.

[0022] By adopting the above technical solution, the electrical connections between the image acquisition module and the light source are unified on the control board, which is then connected to the plug on the outside of the housing, achieving a unified external connection. The wiring is all located within the internal space enclosed by the top cover and the base, eliminating the need for additional openings on the housing for external connections, thus effectively improving the overall sealing performance. Furthermore, the unified electrical connection structure reduces the number of external plugs, making the overall structure of the device simpler and more compact, facilitating installation on welding robots.

[0023] Optionally, a folded optical path assembly is provided inside the housing, and the folded optical path assembly is located between the image acquisition module and the image splitting optical element.

[0024] By adopting the above technical solution, the propagation path of light is changed through optical path folding, thereby effectively shortening the overall length of the device along the optical axis. This allows for a reduction in device size while maintaining imaging quality, resulting in a more compact overall structure and making it more suitable for installation in space-constrained environments such as welding robots.

[0025] Optionally, a filter is provided inside the housing.

[0026] By adopting the above technical solution, the filter only allows light of the corresponding wavelength of the supplementary laser to pass through, thereby effectively filtering out strong arc light and other stray light interference generated during the welding process, which is more conducive to subsequent image recognition and three-dimensional reconstruction processing.

[0027] In summary, this application includes at least one of the following beneficial technical effects: 1. Employing image-splitting optical elements to achieve dual-view imaging with a single camera not only saves overall installation space and simplifies the system structure, but also allows for full utilization of the camera's photosensitive surface, improving the utilization rate of camera pixels. Simultaneously, the entire device can be mounted on the end effector of a welding robot, enabling real-time acquisition of a three-dimensional image of the molten pool as the welding torch moves, further ensuring the stability and synchronization of imaging. 2. The light sources are set in pairs and arranged symmetrically about the axis of symmetry of the split-image optical element, so that the molten pool area can obtain a balanced illumination intensity from left to right. The image acquisition module, split-image optical element and light source can move synchronously with the movement of the welding robot, and maintain a fixed imaging angle and stable illumination position throughout the welding or additive manufacturing process. Thus, when using a single camera for dual-view imaging, the brightness difference between the left and right views is significantly reduced, ensuring the consistency and reliability of the two images in the feature matching process. 3. During installation, the image acquisition module can be fixed to the base. The image splitting optical element is securely installed inside the housing using the mounting part and the first fixing component. Then, a protective lens is installed using the second fixing component to protect the light source and the image splitting optical element. The overall assembly process is simplified and installation is convenient. Furthermore, it can be directly integrated with existing cameras or optical components, offering strong versatility and adaptability, facilitating the expansion of applications for different models of equipment. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the overall structure of Embodiment 1 of this application.

[0029] Figure 2 This is a schematic diagram of the structure of the image-splitting optical element used in Embodiment 1 of this application.

[0030] Figure 3 This is a schematic diagram of the overall structure of Embodiment 2 of this application.

[0031] Figure 4 This is an exploded left view of Embodiment 2 of this application.

[0032] Figure 5 These are photographic renderings of an embodiment of this application.

[0033] Figure 6 This is a diagram showing the effect of image processing in an embodiment of this application.

[0034] Explanation of reference numerals in the attached drawings: 1. Housing; 11. Base; 111. Second wiring port; 112. Protrusion; 113. Insertion slot; 114. Protective lens positioning slot; 12. Top cover; 121. Fixing slot; 122. Receiving groove; 13. Mounting part; 131. Optical element positioning slot; 132. Optical element mounting base; 14. First fixing member; 141. First clamping frame; 142. First fixing frame; 15. Second fixing member; 151. Protective lens mounting frame; 152. Second clamping frame; 153. Second fixing frame; 16. Positioning part; 161. First connecting hole; 162. Second connecting hole; 17. Optical group power supply module; 18. Plug; 19. Control board; 2. Image acquisition module; 3. Image splitting optical element; 4. Light source; 5. Protective lens; 6. Folding optical path assembly; 7. Protective cover; 71. First wiring port; 72. Annular groove; 8. Support bracket. Detailed Implementation

[0035] The following is in conjunction with the appendix Figure 1-6 This application will be described in further detail.

[0036] This application discloses a 3D molten pool real-time imaging device.

[0037] like Figure 1 and Figure 2The 3D molten pool real-time imaging device includes a housing 1, on which an image acquisition module 2, a splitting optical element 3, and a light source 4 are provided. The splitting optical element 3 is used to split the light in the area of ​​the molten pool to be measured into left and right paths. The image acquisition module 2 is used to acquire the light signal after being split by the splitting optical element 3 and form left and right view images. At least one pair of light sources 4 are provided, and the light sources 4 in the same pair are symmetrically arranged about the axis of symmetry of the splitting optical element 3.

[0038] The image acquisition module 2 is installed and fixed inside the housing 1 and is located near the rear end of the housing 1. The image acquisition module 2 can be any imaging module, specifically an industrial camera or a trigger camera. The built-in image sensor of the camera is usually a CMOS or CCD, preferably a global shutter image sensor, which is suitable for capturing fast-changing dynamic images.

[0039] The image-splitting optical element 3 is fixedly mounted on the front end of the housing 1. The image-splitting optical element 3 can be a single prism, specifically an isosceles prism. To meet the optical path deflection requirements for single-camera dual-view imaging, the apex angle of the prism must be obtuse and limited to the range of 110° to 170°. During installation, it is preferable to position the bottom surface of the prism away from the image acquisition module 2, and the top edge of the prism (i.e., the edge where the two sides of the prism intersect) towards the image acquisition module 2. Alternatively, the bottom surface of the prism can be positioned towards the image acquisition module 2, with the prism normal collinear with the optical axis of the image acquisition module 2. The prism normal refers to the extension of the line connecting the midpoint of the top edge of the prism to the midpoint of the bottom surface of the prism. The image-splitting optical element 3 can also be a pair of symmetrically arranged mirrors, with the axis of symmetry of the pair of mirrors collinear with the optical axis of the image acquisition module 2. Alternatively, it can be a combination of symmetrical mirrors and a combining prism.

[0040] The light source 4 can be installed on the outer wall of the housing 1 or fixed inside the housing 1. Preferably, the light source 4 is installed at the front end of the housing 1, and the light source 4 is closer to the shooting area than the image splitting optical element 3. This avoids the incident angle of the light source 4 being blocked by other components during adjustment, and helps to increase the adjustment range of the incident angle of the light source 4. The two optical paths of the same pair of light sources 4 are arranged about the axis of symmetry of the image splitting optical element 3, and just illuminate the object being photographed. For example, the molten pool light rays incident at an angle of ±15° to the axis of the welding torch.

[0041] The light sources 4 of the same pair are symmetrically arranged about the axis of symmetry of the image-splitting optical element 3. Specifically, if the image-splitting optical element 3 is a prism, the two light sources 4 are symmetrically arranged about the normal of the prism, which is also the axis of symmetry of the two sides of the prism. If the image-splitting optical element 3 is a pair of mirrors, the two light sources 4 are symmetrically arranged about the axis of symmetry of the pair of mirrors. That is, the two light sources 4 of the same pair can be arranged on the left and right sides of the image-splitting optical element 3, or on the top and bottom sides of the image-splitting optical element 3. Alternatively, two pairs of light sources 4 can be used, with each of the four light sources 4 located at a corner of the housing 1, or two light sources 4 can be arranged on one side of the housing 1, and the other two light sources 4 can be arranged on the other side of the housing 1. Using extra light sources 4 can not only enhance the illumination, but also allow multiple light sources 4 on the same side to operate alternately, avoiding the significant heat generated by a single light source 4 on the same side working for a long time, which would affect the lighting effect.

[0042] Light source 4 employs a pulsed laser that is precisely synchronized with the camera's exposure. Synchronization can be achieved through various means, such as controlling laser emission via the camera's output signal or through a controller for light source 4. The laser wavelength is positioned far from the peak region of the arc light spectrum and within the sensitive region of the camera's sensor spectrum. This minimizes the impact of the arc light on the image and ensures image quality. The low-light laser illumination band is 600-650nm, but can also be 900-1000nm.

[0043] The housing 1 is also provided with a protective lens 5, which covers the light-emitting area of ​​the image splitting optical element 3 and the light source 4. The housing 1 includes a base 11, a top cover 12, a mounting part 13, a first fixing member 14, and a second fixing member 15. The base 11 and the top cover 12 form an internal space for accommodating the image acquisition module 2. The mounting part 13 is used to accommodate the image splitting optical element 3. The first fixing member 14 is used to fix the image splitting optical element 3. The second fixing member 15 is located at the front end of the base 11 and is used to install the protective lens 5. It also includes a positioning part 16, on which the image acquisition module 2 is mounted. When the first fixing member 14 fixes the image splitting optical element 3, the optical axis of the image acquisition module 2 is coaxial with the axis of symmetry of the image splitting optical element 3.

[0044] Specifically, the protective lens 5 is mounted on the front end of the housing 1 via the second fixing member 15, and the light source 4 and the image splitting optical element 3 are located between the protective lens 5 and the image acquisition module 2. The area of ​​the protective lens 5 should be larger than the total area occupied by the image splitting optical element 3 and the light source 4. The protective lens 5 can be a single piece of lens customized according to the actual assembly requirements, or it can be assembled from multiple lenses based on existing inventory.

[0045] The base 11 can be a plate structure and the top cover 12 can be a cover structure. Alternatively, the base 11 can be a box structure with an open top and the top cover 12 can be a cover structure.

[0046] The mounting part 13 can be a slot opened on the base 11 / top cover 12 to accommodate the image splitting optical element 3, and the optical element positioning slot 131 is adapted to the slot. The mounting part 13 can also be a lens mount structure, in which the image splitting optical element 3 is placed in the lens mount, and then the lens mount is fixed to the base 11 / top cover 12.

[0047] The first fixing member 14 can be a frame structure, connecting the frame to the base 11 / top cover 12 / lens mount to press the image-splitting optical element 3. The frame can be connected to the base 11 / top cover 12 / lens mount with bolts to achieve the pressing function. Alternatively, the second fixing member 15 can press the protective lens 5, and the protective lens 5 presses the frame to achieve the pressing function. Alternatively, the frame can be fixed to the base 11, with a limiting slot on the base 11, so that when the lens is inserted into the limiting slot, the frame automatically presses the image-splitting optical element 3. The first fixing member 14 can also be glued (e.g., UV glue) to directly fix the image-splitting optical element 3 to the base 11 / cover / lens mount. Alternatively, a bolt or screw structure can be used to finely adjust the left and right positions and press against the image-splitting optical element 3 to achieve a fixing effect. The bolt or screw structure can be installed at the front end of the base 11 / top cover 12.

[0048] The second fixing member 15 can be an independent clamping frame structure, pressing the protective lens 5 into the clamping frame, and then connecting the clamping frame to the base 11 / upper cover / first fixing member 14. The second fixing member 15 can also be a single frame structure, with a groove on the base 11 / upper cover 12 for accommodating the protective lens 5, and the frame connected to the base 11 / upper cover 12 to press the protective lens 5. Alternatively, the frame can press the protective lens 5, and the protective lens 5 can press the first fixing member 14, thereby fixing the lens.

[0049] The positioning part 16 can be a positioning hole formed on the base 11 / upper cover, so that the image acquisition module 2 can be fixed to the base 11 / upper cover by bolts through the positioning hole. Alternatively, it can be a positioning groove formed by the base 11 / upper cover that is adapted to the image acquisition module 2.

[0050] like Figure 3 and Figure 4 The housing 1 also contains a folded optical path assembly 6, which is located between the image acquisition module 2 and the image splitting optical element 3. The optical axis of the folded optical path assembly 6 is coaxial with the optical axis of the image acquisition module 2. The folded optical path assembly 6 can be a lens group or a prism group, that is, a combination of lenses that can refract and converge light.

[0051] It also includes a filter (not shown in the figure), specifically a narrowband filter, which can be integrated between the image sensor (CMOS / CCD) and the lens, or it can be fixed independently in the housing 1, located in front of the lens and the folding optical path assembly 6 / pixelation optical element 3, or it can be located in front of the pixelation optical element 3. In short, as long as the filter is located in the optical path.

[0052] The light source 4 can be directly wired to an external controller, or it can be connected to the optical power supply module 17, which will then provide a unified external power supply. The image sensor can also be directly wired to an external controller. This connection method is suitable for existing independent light sources 4 and common 2D industrial cameras on the market. After installing the existing independent light source 4 and the commercially available 2D industrial camera into the housing 1, it can be easily connected to the existing welding robot control system or intelligent welding platform. This can be used as a demo version structure design for early feasibility testing, making it more versatile.

[0053] To improve its sealing performance, a plug 18 can be provided on the housing 1, and a control board 19 can be installed inside the housing 1. The light source 4 is connected to the control board 19, and the image sensor is also connected to the control board 19. The control board 19 is then connected to the plug 18, and all external connections are made through the plug 18. The control board 19 includes a light source 4 control circuit for driving the light source 4, a signal interface circuit for communicating with the image acquisition module 2, and a power conversion module.

[0054] The implementation principle of this application embodiment is as follows: The image-splitting optical element 3 is precisely positioned in front of the camera lens, integrating and projecting molten pool light rays incident from two different angles onto different areas of the same camera's image sensor. Thus, the camera can simultaneously capture molten pool images from two angles in a single exposure. The light sources 4 are arranged in pairs and symmetrically about the axis of symmetry of the image-splitting optical element 3, ensuring balanced illumination intensity across the molten pool area, resulting in better image quality. The subsequent image processing unit identifies and segments the two sub-images on the sensor. The imaging effect of this device is as follows: Figure 5 As shown, the image, after processing, becomes... Figure 6 As shown in the image (the difference in brightness is due to the background; the actual brightness of the object being photographed is uniform, indicating that the lighting is even), the image captured by this device is clear and of high quality. Then, using a pre-calibrated binocular stereo vision algorithm, parallax is calculated, and the 3D point cloud data of the molten pool is finally reconstructed. Due to the better image quality, accurate data is easier to calculate and extract.

[0055] Example 1 Embodiment 1 of this application discloses a 3D molten pool real-time imaging device.

[0056] like Figure 1 and Figure 2The 3D molten pool real-time imaging device includes a housing 1, which includes a base 11 and a top cover 12. The base 11 is an L-shaped plate structure, and the top cover 12 is a cover structure with an opening at the bottom. The vertical plate of the base 11 is provided with a positioning part 16, which is a first connecting hole 161 opened on the vertical plate of the base 11. The image acquisition module 2 is an industrial camera. The image acquisition module 2 is fixed on the vertical plate of the base 11 through the first connecting hole 161. The vertical plate of the base 11 is provided with a second wiring port 111 to facilitate the external connection of the industrial camera circuit.

[0057] The top cover 12 is bolted to the base 11. A fixing groove 121 is provided on the top of the top cover 12, extending through the top of the top cover 12, the front end face of the top cover 12, and both sides of the front end face of the top cover 12. A mounting part 13 is provided at the front end of the top cover 12. The mounting part 13 includes an optical element positioning groove 131 provided on the front end face of the top cover 12, and receiving grooves 122 are provided on both sides of the front end face of the top cover 12.

[0058] The power supply module 17 of the optical group is bolted in the fixing groove 121 of the upper cover 12. There are two pairs of light sources 4. One pair of light sources 4 is bolted in a receiving groove 122. Support brackets 8 are bolted to both sides of the upper cover 12. The other pair of light sources 4 is bolted to a support bracket 8. The support bracket 8 is an L-shaped plate and is flush with the mounting surface of the receiving groove 122.

[0059] The image-splitting optical element 3 is a prism, which is installed in the optical element positioning slot 131. The first fixing member 14 includes a first clamping frame 141, which is bolted to the front end of the upper cover 12 and clamps the prism. When the upper cover 12 is connected to the base 11, the prism normal is coaxial with the optical axis of the industrial camera. Furthermore, the two light sources 4 in the same pair are symmetrically arranged about the prism normal.

[0060] The second fastener 15 includes a protective lens mounting frame 151 and a second clamping frame 152. The protective lens 5 is located between the protective lens mounting shell and the second clamping frame 152. The protective lens mounting frame 151 is bolted to the second clamping frame 152, so that the protective lens 5 is clamped between the protective lens mounting frame 151 and the second clamping frame 152.

[0061] A protective cover 7 is bolted to the top cover 12. The end of the protective cover 7 facing away from the first fixing member 14 has a first wiring port 71. The end of the protective cover 7 facing the first fixing member 14 has a T-shaped plate structure, and an annular groove 72 is formed in the T-shaped plate structure. During installation, the wiring harnesses of the light source 4 and the optical power supply module 17 are arranged within the fixing groove 121. Then, the protective cover 7 is placed on top, covering the optical power supply module 17 and pressing the wiring harnesses. Simultaneously, the top edges of the protective mirror mounting frame 151 and the second clamping frame 152 are clamped within the annular groove 72, thus fixing the protective mirror mounting frame 151 and the second clamping frame 152.

[0062] The protective mirror mounting frame 151 can also be integrally formed with the first clamping frame 141, and the protective mirror mounting frame 151 and the first clamping frame 141 are simultaneously bolted to the front end of the upper cover 12. The annular groove 72 of the protective cover 7 further strengthens the fixation of the protective mirror mounting frame 151 and the first clamping frame 141.

[0063] The structural design features of Embodiment 1 of this application are that it adapts to the previous independent light source 4 and independent power supply, and the front protective mirror is made from stock. Therefore, its structural design takes more consideration of versatility. The structure is 3D printed and is used as a demo version structural design for early feasibility testing, making it more applicable.

[0064] Example 2 Embodiment 2 of this application discloses a 3D molten pool real-time imaging device.

[0065] like Figure 3 and Figure 4 The 3D molten pool real-time imaging device includes a housing 1, which includes a base 11 and a top cover 12. The base 11 is a box structure with an open top, and the top cover 12 is a plate structure. A positioning part 16 is disposed on the rear end face of the base 11, and the positioning part 16 is a second connecting hole 162 opened on the rear end face of the base 11. The image acquisition module 2 is an industrial camera, and the image acquisition module 2 is fixed to the rear end face of the base 11 through the second connecting hole 162. Protrusions 112 are connected to the two inner sidewalls of the base 11 near its front end. The protrusions 112 are connected to the inner sidewalls of the base 11, and an insertion groove 113 is formed on the inner wall of the front end face of the base 11.

[0066] The mounting part 13 includes an optical element mounting base 132. The image splitting optical element 3 is a triangular prism. The image splitting optical element 3 is installed in the optical element mounting base 132. The optical element mounting base 132 is inserted into the insertion slot 113 and is bolted to the base 11. The first fixing member 14 includes a first fixing frame 142. The first fixing frame 142 cooperates with the optical element mounting base 132 to press the image splitting optical element 3.

[0067] Specifically, the first fixing frame 142 can be integrally formed with the base 11 and located within the insertion slot 113. During installation, the optical element mounting base 132 is tightly inserted into the insertion slot 113 to complete the mating and fixing of the first fixing frame 142 and the optical element mounting base 132. In other embodiments, the first fixing frame 142 can also be directly bolted to the optical element mounting base 132 and then installed together into the base 11.

[0068] In this embodiment, the light source 4 is a pair, and the two light sources 4 are bolted / glued to one side of the optical element mounting base 132. When the optical element mounting base 132 is fixed in the base 11 and the image acquisition module 2 is fixed in the base 11, the prism normal of the prism is coaxial with the optical axis of the industrial camera, and the two light sources 4 are symmetrically arranged about the prism normal of the prism.

[0069] The second fixing component 15 includes a second fixing frame 153. A protective lens positioning groove 114 is provided on the end face of the base 11. The second fixing frame 153 is bolted to the front end of the base 11. The second fixing frame 153 cooperates with the base 11 to press the protective lens 5.

[0070] An industrial camera, a control board 19, and an optical path folding assembly are sequentially arranged on the base 11 along its rear end to the protrusion 112. In this embodiment, the folding optical path assembly 6 is a lens group. A space is left between the protrusion 112 and the bottom surface of the base 11. The ribbon cable of the light source 4 passes through the space between the protrusion 112 and the base 11 and connects to the control board 19. The industrial camera is electrically connected to the control assembly. A plug 18 is installed on the top of the cover 12, and the plug 18 is electrically connected to the control board 19.

[0071] The structural features of Embodiment 2 of this application are that it adopts a customized mirror group, light source 4, and control board 19. The structural design takes into account the feasibility of processing, and the structure is more compact and has stronger sealing (protection against industrial dust).

[0072] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A 3D molten pool real-time imaging device, characterized in that: It includes a housing (1), on which an image acquisition module (2), a splitting optical element (3), and a light source (4) are disposed; The image splitting optical element (3) is used to split the light from the tested molten pool area into left and right paths; The image acquisition module (2) is used to acquire the light signal after it has been imaged by the image splitting optical element (3) and form left and right view images; At least one pair of light sources (4) are provided, and the light sources (4) of the same pair are symmetrically arranged about the axis of symmetry of the image splitting optical element (3).

2. The 3D molten pool real-time imaging device according to claim 1, characterized in that: The housing (1) is also provided with a protective lens (5), which covers the light-emitting area of ​​the image splitting optical element (3) and the light source (4). The housing (1) includes a base (11), a top cover (12), a mounting part (13), a first fixing member (14), and a second fixing member (15). The base (11) and the top cover (12) form an internal space for accommodating the image acquisition module (2); The mounting part (13) is used to accommodate the image splitting optical element (3); The first fixing member (14) is used to fix the image splitting optical element (3); The second fastener (15) is located at the front end of the base (11) and is used to install the protective lens (5); It also includes a positioning part (16), the image acquisition module (2) is installed in the positioning part (16), and when the first fixing member (14) fixes the image splitting optical element (3), the optical axis of the image acquisition module (2) is coaxial with the axis of symmetry of the image splitting optical element (3).

3. The 3D molten pool real-time imaging device according to claim 2, characterized in that: The upper cover (12) is a cover structure. The mounting part (13) includes an optical element positioning groove (131) opened at the front end of the upper cover (12). The first fixing member (14) includes a first pressing frame (141). The first pressing frame (141) is connected to the front end of the upper cover (12). The first pressing frame (141) presses the image splitting optical element (3). The second fastener (15) includes a protective mirror mounting frame (151) and a second clamping frame (152). The protective mirror mounting frame (151) is connected to the front end of the upper cover (12), and the first clamping frame (141) is located between the protective mirror mounting frame (151) and the upper cover (12). The second clamping frame (152) is connected to the protective lens mounting frame (151), and the two together clamp the protective lens (5); The width of the protective mirror mounting frame (151) is greater than the width of the upper cover (12), and the light source (4) is mounted on the upper cover (12); The positioning part (16) includes a first connecting hole (161) provided on the base (11). The image acquisition module (2) is fixed on the base (11) through the first connecting hole (161). When the first pressing frame (141) presses the image splitting optical element (3), the optical axis of the image acquisition module (2) is coaxial with the axis of symmetry of the image splitting optical element (3).

4. The 3D molten pool real-time imaging device according to claim 3, characterized in that: A light group power supply module (17) is installed on the top of the upper cover (12). The light source (4) is connected to the light group power supply module (17). A protective cover (7) is connected to the upper cover (12). The protective cover (7) covers the light group power supply module (17). A first wiring port (71) is opened at the end of the protective cover (7) away from the front end of the upper cover (12). A second wiring port (111) is opened at the end of the base (11) away from the front end of the upper cover (12).

5. The 3D molten pool real-time imaging device according to claim 3, characterized in that: Both sides of the upper cover (12) are connected to support brackets (8), and the light source (4) is installed on both sides of the front end of the support brackets (8) and the upper cover (12).

6. The 3D molten pool real-time imaging device according to claim 4, characterized in that: The protective cover (7) has an annular groove (72), and the second clamping frame (152) and the protective mirror mounting frame (151) are clamped together in the annular groove (72).

7. The 3D molten pool real-time imaging device according to claim 2, characterized in that: The base (11) is a box structure with an open top. Both sides of the base (11) are provided with protrusions (112), and the protrusions (112) and the inner wall of the base (11) form an insertion groove (113). The mounting part (13) includes an optical element mounting base (132), which is inserted into the insertion slot (113). The image splitting optical element (3) is installed in the optical element mounting base (132). The first fixing member (14) includes a first fixing frame (142), which is installed on the optical element mounting base (132). The first fixing frame (142) cooperates with the optical element mounting base (132) to press the image splitting optical element (3). The light source (4) is mounted on both sides of the optical element mounting base (132); The second fixing member (15) includes a second fixing frame (153), and the front end of the base (11) is provided with a protective lens positioning groove (114). The second fixing frame (153) is connected to the front end of the base (11), and the second fixing frame (153) cooperates with the base (11) to press the protective lens (5). The positioning part (16) includes a second connecting hole (162) provided on the base (11). The image acquisition module (2) is fixed on the base (11) through the second connecting hole (162). When the first fixing frame (142) presses the image splitting optical element (3), the optical axis of the image acquisition module (2) is coaxial with the axis of symmetry of the image splitting optical element (3).

8. The 3D molten pool real-time imaging device according to claim 1, characterized in that: A control board (19) is installed inside the housing (1), and a plug (18) is installed on the housing (1). The image acquisition module (2), the image splitting optical element (3), and the light source (4) are all electrically connected to the control board (19).

9. The 3D molten pool real-time imaging device according to claim 1, characterized in that: The housing (1) is provided with a folded optical path assembly (6), which is located between the image acquisition module (2) and the image splitting optical element (3).

10. The 3D molten pool real-time imaging device according to claim 1, characterized in that: A filter is provided inside the housing (1).

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