Arc-Tracking Camera Control for Manual Welding Measurement
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Solution Overview
Problem
Existing welding measurement systems struggle to steadily capture the welding phenomenon in manual arc welding, especially when the torch's moving speed changes irregularly, due to challenges in maintaining a consistent photographing distance and angle, and adjusting image processing parameters.
Innovation Solution
A welding measuring system comprising a camera rail, a movable camera, and a computer that controls the camera's movement to keep the arc within a predetermined region of the image, allowing for continuous photography even as the torch speed varies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the camera moves at a predetermined model speed, then the camera can be easily controlled, but the photographing distance and angle vary when the torch speed changes, causing unstable welding phenomenon capture
Solution Approach 1:
The system uses image processing to detect the torch position in each captured frame, calculates the torch movement speed, and feeds this information back to adjust the camera speed. This closed-loop feedback mechanism ensures the camera automatically adapts to varying torch speeds, maintaining stable welding phenomenon capture without requiring manual intervention.
Solution Approach 2:
The camera speed is transformed from a fixed predetermined value to a dynamic value that changes according to the detected torch speed. The system continuously adjusts the camera's movement characteristics to match the welding process dynamics, enabling stable tracking regardless of torch speed variations.
2Reliability
If the camera speed is synchronized with the welding torch speed calculated from whole behavior camera images, then the welding phenomenon can be captured steadily, but it takes time to calculate the torch speed from image information
Solution Approach 1:
The system performs image processing and torch position detection on each captured frame immediately, preparing the data for speed calculation in advance. By continuously processing images and maintaining a buffer of detected positions, the system reduces the computational delay when speed calculation is needed for camera synchronization.
Solution Approach 2:
The system replaces complex mechanical speed sensing mechanisms with optical image processing and computational analysis. By using the first camera's images to detect torch position and calculate speed through image analysis algorithms, the system achieves accurate speed synchronization without additional mechanical sensors or complex mechanical linkages.
3Adaptability or versatility
If the camera arrangement or welding position changes, then the imaging conditions change, but image processing parameters need to be adjusted again, reducing system adaptability
Solution Approach 1:
The system automatically detects torch position and calculates movement characteristics from the captured images without requiring external parameter input or manual adjustment. The image processing algorithms self-adapt to different camera arrangements and welding positions by analyzing the actual torch movement patterns observed in the images, eliminating the need for complex parameter reconfiguration.
Solution Approach 2:
The system dynamically adjusts image processing parameters based on the detected torch movement characteristics and imaging conditions. By continuously optimizing parameters such as detection thresholds and processing algorithms based on actual observed conditions, the system maintains high adaptability across different welding scenarios without requiring manual parameter changes.
Data Source
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.