Arc-Tracking Camera Rail for Stable Manual Welding Imaging
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Solution Overview
Problem
Existing welding skill evaluation systems struggle to steadily photograph welding phenomena when the moving speed of the torch changes irregularly, leading to variations in photographing distance and angle, and require time-consuming adjustments for imaging conditions.
Innovation Solution
A welding measuring system with a first camera rail, a movable first camera, and a camera driving device, controlled by a computer to maintain the arc within a predetermined image region, ensuring consistent photography.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the camera moves at a predetermined model speed, then the camera can be controlled in a simple manner, but the photographing distance and angle vary when torch speed changes, causing unstable welding phenomenon capture
Solution Approach 1:
The system uses feedback control by detecting the arc position in each captured image and adjusting the camera's movement speed to keep the arc within a predetermined region. The computer calculates the arc position, determines the required camera speed to maintain the arc in the target region, and controls the camera driving device accordingly. This closed-loop feedback mechanism resolves the contradiction by adapting camera speed to actual welding conditions rather than using a fixed predetermined speed.
2Reliability
If the camera speed is synchronized with torch speed calculated from whole behavior camera images, then the welding phenomenon can be captured steadily, but it takes time to calculate torch speed from image information
Solution Approach 1:
The system replaces the mechanical approach of calculating torch speed from whole behavior camera images with an optical/electronic approach by directly detecting the arc position in the captured images. Instead of analyzing torch movement through image processing of the whole behavior camera, the system uses the arc's luminance characteristics to directly determine position and calculate required camera speed, significantly reducing computation time while maintaining steady capture.
3Adaptability or versatility
If the camera arrangement or welding position changes, then the system can adapt to different welding scenarios, but image processing parameters need to be adjusted again, reducing efficiency
Solution Approach 1:
The system implements self-service by automatically detecting arc position and calculating required camera movement parameters in real-time without requiring manual parameter adjustments. The computer continuously analyzes the captured images, determines arc position, and autonomously controls the camera driving device to maintain optimal imaging conditions, enabling the system to adapt to different welding scenarios without human intervention.
Data Source
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AI summary
An object of the present invention is to provide a welding measuring system and a welding measuring method that can steadily photograph a welding phenomenon in manual arc welding in which the moving speed of a torch changes irregularly. To this end, a welding measuring system for measuring a welding phenomenon in manual arc welding includes: a camera rail disposed along a welding line; a camera movable on the camera rail; a camera driving device that drives the camera; and a computer that senses a position of an arc within an image photographed by the camera, and controls the camera driving device such that the camera moves at a speed at which the position of the arc continues to be displayed within a predetermined region within the image photographed by the camera.