Multi-Wavelength Brazing Analysis for Flame-Free Heating Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for analyzing brazing tasks face challenges in accurately determining the heating state of materials due to disturbances caused by flames and scattered components, which affect the quality of brazed products.
Innovation Solution
A method utilizing two different wavelength bands of optical images to distinguish between the color of flames and heated materials, allowing for precise determination of analysis periods free from disturbances, and ensuring sufficient and uniform heating of brazing materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If single wavelength band imaging is used to analyze brazing task, then device complexity is reduced, but measurement precision of heating state deteriorates due to flame disturbances
Solution Approach 1:
The imaging system is segmented into multiple wavelength band detectors, each capturing specific wavelength ranges. This segmentation allows the system to separate flame emission signals from heated material signals, improving measurement precision without requiring a single complex detector to handle all wavelengths simultaneously.
Solution Approach 2:
The system adds the wavelength dimension to the traditional spatial imaging approach. By capturing images across multiple wavelength bands, the system distinguishes between different heat sources (flame vs. heated material) based on their spectral characteristics, thereby improving heating state determination accuracy.
2Measurement precision
If multiple wavelength bands are used to distinguish flame from heated material, then measurement precision improves, but device complexity increases
Solution Approach 1:
The imaging system is segmented into multiple wavelength band detectors, each capturing specific wavelength ranges. This segmentation allows the system to separate flame emission signals from heated material signals, improving measurement precision without requiring a single complex detector to handle all wavelengths simultaneously.
Solution Approach 2:
The system changes the wavelength parameter of the captured images by using multiple wavelength bands. This allows differentiation between flame and heated material based on their distinct spectral emission characteristics, improving the accuracy of heating state determination while managing device complexity through parameter variation.
3Productivity
If images during flame disturbance periods are used for analysis, then productivity is maintained by continuous monitoring, but measurement precision deteriorates due to analysis errors
Solution Approach 1:
The system performs preliminary identification of flame disturbance periods by analyzing characteristics of images captured during brazing. This preliminary action allows the system to flag and exclude images taken during flame disturbances from the heating state analysis, preventing measurement errors while maintaining continuous monitoring capability.
Solution Approach 2:
The system uses feedback from multi-wavelength image analysis to identify when flame disturbances are occurring. This feedback mechanism allows the system to adjust its analysis by excluding compromised images, thereby maintaining both continuous monitoring productivity and measurement precision by adaptively processing only valid data.
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
Enhances the accuracy of determining the heating state of brazing materials, reducing the risk of improper brazing and improving the quality of brazed joints by minimizing interference from flame disturbances.
Implementation Method 1
As shown in FIGS. 4A and 4B, when an object is heated, its color changes depending on its temperature. Therefore, by imaging the brazing task using a plurality of images of different wavelength bands, it is possible to determine an analysis period free from disturbances and to perform determination of a heating state of materials to be brazed
Data Source
AI summary
According to one embodiment, an analysis method analyzes a brazing task of first and second members. In the method, a computer acquires a first image of a first wavelength band and a second image of a second wavelength band, the second wavelength band having a longer wavelength than the first wavelength band. The computer determines a first period based on pixel values including a pixel value of the first image and a pixel value of one or more of the first images acquired previously, a disturbance to the analysis occurring in the first period. The computer determines whether a timing at which the second image is imaged is included in the first period. When the timing is not included in the first period, the computer uses the second image to determine whether heating states of the first and second members are sufficient.