Arc Welding Spatter Detection Using Single-Image Bright Spot Exclusion
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Solution Overview
Problem
Existing arc welding techniques require high-speed video cameras to accurately detect spatters, leading to increased equipment costs and reduced accuracy due to the need for multiple input images.
Innovation Solution
A device that assists in setting welding conditions by detecting spatters from a single input image using an image processing unit, identifying background bright spots, and excluding reflected light, allowing for accurate spatter detection without the need for high-speed cameras.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple input images are used to detect spatters, then the accuracy of spatter detection is improved, but the capturing speed requirement increases and equipment cost increases
Solution Approach 1:
The invention extracts only the necessary information (spatter detection) from a single input image by using a predetermined detection line, rather than requiring multiple images. This extraction approach allows accurate spatter counting to be achieved with simpler, lower-cost imaging equipment.
Solution Approach 2:
The detection process is segmented by defining a specific detection line through the molten pool region, focusing analysis only on the relevant area where spatters pass. This segmentation enables accurate measurement without needing to capture the entire scene in multiple frames.
2Measurement precision
If multiple input images are used to detect spatters, then the accuracy of spatter identification is improved, but the capturing speed requirement increases
Solution Approach 1:
The invention extracts spatter information from a single image frame by analyzing luminance distribution along a predetermined detection line. This extraction method achieves accurate spatter identification without requiring high-speed capturing of multiple frames.
Solution Approach 2:
Instead of analyzing the entire image or requiring multiple frames, the invention performs partial action by focusing only on the detection line passing through the molten pool region. This selective analysis achieves sufficient accuracy with lower capturing speed requirements.
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
Reduces equipment costs by enabling spatter detection from a single image, improving accuracy in identifying spatters larger than a predetermined size, and facilitating the reduction of large spatters, while accurately differentiating between true spatters and reflected light.
Implementation Method 1
takes in a luminance distribution on a predetermined detection line in the image for each input image, and detects spatters passing on the detection line based on the luminance distribution
Implementation Method 2
the moving image being generated by capturing the workpiece during the arc welding
Data Source
AI summary
Image processing unit is provided in computer, and performs: for each of input images constituting a moving image obtained by capturing a workpiece during arc welding, a spatter detection step of detecting a spatter from an input image constituting a moving image of the workpiece, the moving image being generated by capturing the workpiece during the arc welding; a background bright spot identification step of identifying, as a background bright spot, a position in the moving image, the position being a position where a number of times of the detection in the spatter detection step is equal to or more than a predetermined reference number of times; and a spatter number identification step of identifying, for one input image, a number of spatters excluding spatters each corresponding to the background bright spot identified by the background bright spot identification step among the spatters detected by the spatter detection processing.