Camera Image Section Selection for Real-Time Laser Seam Tracking
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Solution Overview
Problem
Existing laser material processing methods, particularly in remote laser welding, face challenges in efficiently monitoring and controlling the process in a three-dimensional space, requiring real-time image processing and accurate seam tracking without relying on nominal image data, and struggle with data reduction and computational efficiency.
Innovation Solution
A method involving real-time image recording by a camera on the laser material processing head, determining relevant image sections, calculating deviations, and using programmed path data to predict and correct future positions, allowing for precise control and quality assurance before, during, and after the process, with reduced data transmission and processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire camera image is recorded and transmitted for monitoring laser material processing, then complete process information is available, but data transmission volume and computational effort increase significantly
Solution Approach 1:
The patent divides the camera image into multiple sections and selectively transmits only those sections that contain relevant process information. The image processing system identifies and extracts specific regions of interest (such as the seam area, keyhole, or processing zone) from the full image, thereby segmenting the data transmission task into manageable, relevant portions that reduce overall data volume while maintaining monitoring reliability.
Solution Approach 2:
The patent extracts only the necessary image sections containing process-relevant information (such as the seam trajectory, keyhole characteristics, or material edge) from the complete camera image. By taking out and transmitting only these critical sections rather than the entire image, the system reduces data transmission requirements and computational load while preserving the essential information needed for process monitoring and control.
2Measurement precision
If real-time image processing is performed on the entire image, then accurate seam tracking is achieved, but processing time increases
Solution Approach 1:
The patent segments the image processing task by identifying and processing only the relevant sections containing seam information. Instead of analyzing the entire image, the system divides the processing workload into focused operations on specific regions (such as the seam line, adjacent material areas, and keyhole zones), thereby maintaining tracking accuracy while significantly reducing the time required for image analysis.
Solution Approach 2:
The patent applies partial action by processing only the necessary portions of the image that contain seam-relevant information. Rather than performing exhaustive processing on the complete image, the system selectively applies image processing algorithms to specific sections where seam tracking data is located, achieving accurate seam tracking with reduced processing time by avoiding unnecessary computation on irrelevant image areas.
3Adaptability or versatility
If the camera records the complete workpiece area, then all potential seam positions are captured, but data transmission and storage requirements increase
Solution Approach 1:
The patent segments the camera field of view into multiple sections and selectively transmits only those sections where seams are detected or expected. By dividing the workpiece area into manageable regions and identifying which segments contain relevant seam information, the system maintains comprehensive seam position coverage across the entire workpiece while reducing data transmission and storage requirements by excluding empty or irrelevant sections.
Solution Approach 2:
The patent performs preliminary identification of seam positions or regions of interest before completing full image processing. By预先 (in advance) determining which image sections contain seam information based on initial analysis or programmed path data, the system can selectively capture and transmit only those relevant sections, thereby maintaining adaptability to various seam positions while reducing the overall data volume that requires transmission and storage.
4Manufacturing precision
If high-resolution images are recorded for quality control, then detailed process information is available, but computational effort for analysis increases
Solution Approach 1:
The patent segments the high-resolution image into multiple sections and processes only those sections that contain quality-relevant information (such as the seam area, fusion zone, or critical dimensions). By dividing the detailed image into manageable segments and applying quality control analysis only to relevant portions, the system maintains manufacturing precision for quality assessment while reducing the overall computational effort required for complete image analysis.
Solution Approach 2:
The patent extracts and isolates the specific image sections containing quality-critical information (such as seam quality, keyhole characteristics, or dimensional accuracy) from the complete high-resolution image. By taking out only these essential sections for detailed analysis rather than processing the entire high-resolution image, the system achieves accurate quality control with reduced computational effort, focusing processing resources on the most critical quality-determining areas.
Data Source
AI summary
A method for monitoring the process in laser material processing and provides a corresponding method, comprising the steps of taking a real-time image comprising the position and surrounding of the process where material processing occurs by a camera that is arranged in or on a laser material processing head; determining at least one image section in the real-time image and its position on a camera sensor; determining an actual position of the process in the material processing, and a nominal position of the relevant image detail using a projection of programmed path data for controlling the laser material processing head in the section of the real-time image, and the transfer of the at least one image section from the camera to a computer.