3D Weld Operation Measurement Using Optical Markers
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Solution Overview
Problem
Existing welding operation measurement systems struggle to accurately measure the positional relationship between a welding target object and a welder, especially when the welding target object has a complex shape, and fail to provide detailed three-dimensional coordinate data.
Innovation Solution
A welding operation measurement system using light irradiation units that emit light of specific wavelengths, combined with self-luminous markers, to accurately measure the positional relationship and acquire three-dimensional coordinate data by filtering reflected light and using marker measurement cameras to calculate precise coordinate data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional measurement devices are used to measure welding operations, then basic movement data can be acquired, but accurate three-dimensional coordinate data and positional relationships cannot be obtained, especially for complex-shaped welding target objects
Solution Approach 1:
The patent introduces markers as intermediary objects attached to both the welding target object and the welding tool. These markers serve as mediators that enable precise measurement of positional relationships by providing identifiable reference points that can be tracked in three-dimensional space, solving the problem of accurately measuring positions on complex-shaped objects.
Solution Approach 2:
The patent transitions from conventional two-dimensional or limited spatial measurement to comprehensive three-dimensional coordinate measurement. By using multiple light irradiation units positioned at different locations and calculating intersection points of light rays, the system achieves full three-dimensional spatial measurement capability, capturing complete positional and orientational information.
2Measurement precision
If multiple light irradiation units are used to measure three-dimensional coordinates, then accurate positional data can be acquired, but the device complexity increases
Solution Approach 1:
The patent designs the light irradiation units to serve multiple functions: they emit light for illumination, serve as measurement devices for detecting marker positions, and function as coordinate reference points themselves. This multi-functionality reduces the need for separate dedicated measurement devices, thereby reducing overall system complexity while maintaining measurement precision.
Solution Approach 2:
The patent replaces complex mechanical measurement systems with an optical measurement system. Instead of using mechanical sensors, contact probes, or complex positioning mechanisms, the system uses light emission and detection to measure three-dimensional coordinates, simplifying the mechanical complexity while achieving high measurement accuracy.
3Reliability
If direct teaching from skilled technicians is used to transfer welding skills, then personal expertise can be conveyed, but the skill transfer is inefficient and may be lost without complete documentation
Solution Approach 1:
The patent implements a feedback mechanism where welding operations are measured and recorded with precise three-dimensional coordinate data. This objective measurement data provides feedback on actual welding techniques and movements, allowing for systematic analysis and documentation of skilled operations, thereby making skill transfer more reliable and efficient through data-driven learning materials.
Solution Approach 2:
The patent creates objective copies of welding operations through three-dimensional coordinate measurement and data recording. Instead of relying on subjective human memory and intuition in skill transfer, the system creates accurate digital copies of welding techniques, movements, and positions that can be stored, analyzed, and transmitted without loss, enabling efficient and reliable skill documentation and transfer.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables accurate measurement of the positional relationship and three-dimensional coordinate data of the welding target object and welder, allowing for precise evaluation and control of welding operations, improving skill transfer and quality control.
Implementation Method 1
a light irradiation unit that emits light having a predetermined wavelength
Implementation Method 2
the three-dimensional coordinate measurement unit measures light reflected from the marker
Data Source
Figure 1
Figure 2A~2B
Figure 3~4
AI summary
It is configured to include: a light irradiation unit that emits light; a three-dimensional coordinate measurement unit that measures light reflected from a marker attached to a work and a torch and calculates three-dimensional coordinate data of the work and the torch, the work or the marker reflecting the emitted light; and an arithmetic unit that converts a shape of the work into coordinates based on input three-dimensional graphic data and the three-dimensional coordinate data of the work and generates coordinate data of a shape of the work.