Autofocus Object Distance Detection for Laser Brazing Positioning

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Solution Overview

Problem

Conventional laser brazing and welding processes require time-consuming and complex adjustments to accurately position the wire feed, leading to suboptimal brazing quality and potential machine damage due to inaccurate positioning.

Innovation Solution

A system utilizing a computing device with an image recognition module and autofocus device to detect and adjust the distance between designated sites on an object, calculating errors and applying focus corrections through a feedback control loop to ensure precise positioning of the laser head.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional manual adjustment methods are used to position the wire feed, then the machine operator can perform the brazing operation, but the tune-in time is time-consuming and positioning accuracy is poor

Engineering Contradiction:

Improvepositioning accuracyVSAvoidtune-in time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical adjustment with an automated optical measurement system. The imaging device captures images of the seam, and image processing algorithms automatically calculate positioning parameters, eliminating the need for manual measurement and adjustment operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system performs self-positioning by automatically analyzing the seam geometry from captured images and calculating the optimal wire feed position. The machine operator only needs to initiate the process, and the system autonomously determines the positioning parameters without requiring manual intervention or expertise.

Inventive Principle:

Principle #25Self-service

2Reliability

If manual adjustment methods are used, then the machine can be operated with simple equipment, but the positioning accuracy suffers and machine damage may occur

Engineering Contradiction:

Improvebrazing qualityVSAvoidequipment complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent introduces an imaging device as an intermediary between the operator and the brazing process. This device captures visual information about the seam and workpiece, which is then processed to determine accurate positioning parameters, serving as a bridge that translates visual data into precise control information.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system replaces complex manual positioning mechanisms with a combination of imaging technology and computational algorithms. Instead of relying on mechanical adjustment devices and operator skill, the system uses optical fields and image processing to achieve precise positioning.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If complex equipment is used to improve positioning accuracy, then the brazing quality improves, but the ease of operation decreases and operator skill requirements increase

Engineering Contradiction:

Improvepositioning accuracyVSAvoidoperator ease of use

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system captures images of the actual seam and workpiece position, processes this visual feedback information, and uses it to calculate accurate positioning parameters. This closed-loop approach ensures that the positioning is based on real-time observations of the actual work conditions.

Inventive Principle:

Principle #23Feedback

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

This method significantly reduces tune-in time, enhances accuracy, and minimizes equipment damage by enabling precise and efficient object distance detection and focal positioning, thereby improving the quality of laser brazing and welding operations.

Implementation Method 1

adjusting a focus (via an autofocus device) onto the plurality of designated sites

Methodology Applied

Scientific EffectAutofocus: Focusing

Implementation Method 2

calculating (via an image recognition module) the actual distance among the plurality of designated sites

Methodology Applied

Scientific EffectImage recognition: Image Processing

Data Source

PatentUS10481577B2System and method for object distance detection and positioning

Publication Date: 2019.11.19 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A method for object distance detection and focal positioning in relation thereto. The method comprising the steps of: (a) identifying (via a computing device) a desired distance among a plurality of designated sites on an object; (b) adjusting a focus (via an autofocus device) onto the plurality of designated sites; (c) calculating (via an image recognition module) the actual distance among the plurality of designated sites; (d) determining (via the image recognition module) if error exist between the actual distance and the desired distance; and (e) wherein (in no particular order) repeating the steps of (b), (c), and (d) until no substantial error exists between the actual distance and the desired distance.