Camera Image Section Selection for Remote Laser Welding Tracking
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Solution Overview
Problem
Current methods for laser material processing, particularly in remote laser welding, face challenges in efficiently monitoring and controlling the process in three-dimensional space, requiring real-time image processing and precise position determination without relying on nominal image data, and often result in increased computational effort and data transmission.
Innovation Solution
A method involving real-time image recording by a camera on the laser material processing head, determining relevant image sections, calculating deviations between actual and nominal positions, and adjusting the processing based on programmed path data to predict and correct future image sections, allowing for efficient monitoring and control of the process before, during, and after welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If the entire camera image is processed and transmitted, then complete information is available for analysis, but data transmission volume and computational effort increase significantly
Solution Approach 1:
The patent divides the camera image into multiple sections and selectively processes only those sections that contain relevant process information. By segmenting the image and applying region-of-interest detection, the system transmits only necessary image data to the control device, reducing overall data volume while maintaining essential information for process monitoring and control.
Solution Approach 2:
The patent extracts and transmits only the relevant image sections containing process-critical information rather than the complete image. The control device identifies and isolates specific regions of interest from the camera image, removing unnecessary data elements and transmitting only the extracted relevant portions, thereby reducing transmission bandwidth requirements and computational load.
2Measurement precision
If real-time image processing is performed on the entire image, then accurate process monitoring is achieved, but processing time and computational resources increase
Solution Approach 1:
The patent segments the image processing task by identifying and processing only relevant sections of the camera image in real-time. By dividing the full image into manageable regions and applying processing algorithms only to those sections containing process information, the system maintains monitoring accuracy while significantly reducing processing time and computational resource requirements.
Solution Approach 2:
The patent applies partial processing by focusing computational resources only on the necessary portions of the image rather than processing the entire image. This selective approach processes only the minimum required data volume to achieve accurate process monitoring, avoiding excessive computation on irrelevant image areas and thereby reducing processing time.
3Loss of energy
If image sections are selected based on programmed path data projection, then data transmission is reduced, but position determination complexity increases
Solution Approach 1:
The patent performs preliminary projection of the programmed path data onto the camera image to pre-identify relevant image sections before actual process monitoring begins. By calculating and marking the expected position of process-relevant areas in advance based on path planning data, the system simplifies real-time position determination and reduces the complexity of dynamic image section selection during operation.
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.