Non-destructive Bead Inspection via Optical Regression
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Solution Overview
Problem
The existing methods for inspecting the throat thickness of beads formed during brazing are destructive, time-consuming, and costly, especially when dealing with small beads, as they require physical measurement and result in increased waste, leading to higher manufacturing costs.
Innovation Solution
A non-destructive bead inspection method and apparatus that calculates the throat thickness using regression expressions based on feature quantities such as bead width, height difference, shrinkage depth, and cross-sectional area, acquired through shape data measurement before and after brazing, without damaging the workpieces or bead, allowing for predictive analysis of the bead's quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If destructive measurement method is used to measure throat thickness, then measurement precision is improved, but productivity deteriorates and loss of substance increases
Solution Approach 1:
The patent replaces the mechanical destructive measurement system with an optical measurement system. A camera captures images of the bead from multiple angles, and image processing algorithms calculate the throat thickness non-destructively. This substitution eliminates the need to cut and physically measure the bead, thereby maintaining measurement precision while dramatically improving productivity by enabling rapid non-contact inspection.
Solution Approach 2:
The patent creates a digital copy (image) of the bead instead of physically destroying it for measurement. By capturing the bead's geometry through imaging and processing these digital copies to calculate throat thickness, the system preserves the original bead while obtaining accurate measurements, thus improving productivity without sacrificing measurement precision.
2Measurement precision
If destructive measurement method is used to measure throat thickness, then measurement precision is improved, but loss of time increases
Solution Approach 1:
The optical imaging and image processing system replaces time-consuming mechanical cutting and manual measurement processes. The camera rapidly captures bead images, and automated algorithms quickly compute throat thickness, reducing inspection time while maintaining measurement precision through digital analysis rather than slow physical measurement.
Solution Approach 2:
The patent performs preliminary imaging of the bead before any measurement action is taken. By capturing the complete geometric information through imaging first, the system enables rapid subsequent calculation of throat thickness without requiring time-consuming physical intervention, thus reducing overall inspection time while preserving measurement accuracy.
3Measurement precision
If destructive measurement method is used to measure throat thickness, then measurement precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive destructive measurement equipment and processes with more economical optical imaging systems. The camera-based approach with automated image processing eliminates costs associated with physical cutting, sample preparation, and manual measurement, thereby reducing manufacturing costs while maintaining measurement precision through advanced digital analysis.
Solution Approach 2:
By creating digital copies of the bead through imaging, the patent eliminates the need for physical sample preparation and destruction. This digital replication approach reduces material waste and associated costs while maintaining measurement precision, thereby improving ease of manufacture and reducing overall manufacturing costs.
4Reliability
If ultrasonic probe method is used for small beads, then non-destructive measurement is achieved, but measurement precision deteriorates
Solution Approach 1:
The patent replaces the ultrasonic probe mechanical system with an optical imaging system that uses light to capture bead geometry. For small beads, the optical system provides superior precision because it can resolve fine geometric details through high-resolution imaging and sophisticated image processing algorithms, while maintaining non-destructive measurement through contactless optical inspection.
Solution Approach 2:
The patent transitions from one-dimensional ultrasonic wave measurement to multi-dimensional optical imaging measurement. By capturing the bead's geometry from multiple angles and processing these multi-dimensional image data, the system achieves higher measurement precision for small beads while maintaining non-destructive inspection through comprehensive geometric analysis.
Data Source
AI summary
A bead inspection step and a bead inspection apparatus that inspect the quality of a bead are disclosed . . . . The bead inspection apparatus includes a wire-feed-speed measurement device that measures the feed speed of a brazing wire, and an analysis portion that measures and analyzes position coordinate data about surfaces of a first, workpiece, a second workpiece and the bead, and performs a first shape data measurement step of. measuring first shape data before brazing, a second shape data measurement step of measuring second shape data after the brazing, a feature quantity calculation step of calculating predicted values of feature quantities based on the first and second shape data and the brazing wire feed speed, and a throat thickness calculation step of calculating a predicted value of the throat thickness by a regression expression formed based on actual measurements of the feature quantities and of the throat thickness.