Dual-Sensor Optical Joint Seam Monitoring
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Solution Overview
Problem
Current optical measuring systems for joint seams struggle to simultaneously perform fast 3D measurement and identify local faults with high resolution during fast object movement, often resulting in suboptimal spatial representation of surfaces, either providing two-dimensional images or topographic images without texture information.
Innovation Solution
An optical measuring device with a light-section device and a second illumination device, featuring a first optical sensor for spatially resolved imaging of a triangulation light line and a second optical sensor for greyscale imaging, both using a common objective lens and having different readout rates to achieve high-resolution, three-dimensional mapping of joint seams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single sensor is used for both fast 3D measurement and high-resolution fault detection, then device complexity is reduced, but measurement precision and detection reliability deteriorate because one sensor cannot simultaneously optimize for both fast temporal resolution and high spatial resolution
Solution Approach 1:
The sensor system is segmented into two specialized sensors: a first sensor optimized for fast 3D measurement with high temporal resolution, and a second sensor optimized for high-resolution fault detection with high spatial resolution. This segmentation allows each sensor to be tuned specifically for its function, resolving the contradiction between device simplicity and measurement precision.
Solution Approach 2:
Both sensors share a common optical path and imaging system, allowing the system to perform multiple functions (fast 3D measurement and high-resolution inspection) through a unified hardware platform. This multi-functionality approach reduces overall device complexity while maintaining the specialized capabilities needed for both measurement tasks.
2Productivity
If the readout rate is increased to capture fast object movement, then productivity and object recognition rate improve, but measurement precision deteriorates due to reduced integration time and increased noise
Solution Approach 1:
The system segments the measurement function into two sensors with different temporal requirements. The first sensor operates at high readout rates for fast 3D measurement during movement, while the second sensor can use longer integration times for high-precision fault detection when needed, thus resolving the contradiction between productivity and precision.
3Device complexity
If a common optical path is used for both sensors, then device complexity is reduced and spatial representation is improved, but the sensors cannot be independently optimized for different measurement requirements
Solution Approach 1:
The optical system is segmented into a common front-end (objective lens, illumination) and separate detection paths for each sensor. This allows the sensors to be independently optimized for their specific measurement requirements while sharing the complex optical components, thus resolving the contradiction between device complexity and adaptability.
Solution Approach 2:
The common optical path serves multiple functions by directing light to both sensors simultaneously, enabling the system to perform both fast 3D measurement and high-resolution inspection through a unified optical platform. This multi-functionality reduces overall complexity while maintaining sensor optimization flexibility.
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
Enables high-resolution, large-object-field measurements with high object-recognition rates, evaluating different or same object regions with distinct sensor properties, and visualizing spatial and textural properties of the joint seam, while allowing for online monitoring or subsequent inspection.
Implementation Method 1
a first optical sensor with a first observation beam path for spatially resolved imaging of the triangulation light line projected onto the joint seam
Implementation Method 2
an illumination device with a second light source for homogeneous illumination of the joining region of the workpiece to be joined
Data Source
AI summary
An optical measuring device for monitoring a joint seam, joining head and laser welding head. The optical measuring device monitors a joining region in a workpiece and has at least one light-section device with a first light source for casting a light fan in the direction of the workpiece to be joined, making a triangulation light line within the joining region which intersects a joint seam. An illumination device with a second light source homogeneously illuminates the joining region. A first optical sensor with a first observation beam path for spatially resolved imaging of the triangulation light line is projected onto the joint seam. A second optical sensor with a second observation beam path for spatially resolved imaging of the joint seam is coaxially coupled with the first observation beam path. The readout rate of the first and second optical sensors is >1 kHz and <500 Hz, respectively.