Handheld Laser Weld Inspection Across Variable Joint Geometries
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current weld surface inspection methods are labor-intensive, require skilled professionals, lack real-time analysis, and are limited by fixed platforms, separate controllers, high computing demands, and external power sources, restricting mobility and flexibility.
Innovation Solution
A handheld laser-based device that projects a thin beam laser light on the weld surface, processes contours in real-time using a processor with integrated statistical algorithms to classify and detect defects, and stores data in cloud storage for remote access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed static platform is used for detection, then the detection device can be stabilized, but the flexibility and adaptability to different welding scenarios is reduced
Solution Approach 1:
The patent transitions from a fixed static platform to a handheld dynamic device that can be manually positioned and oriented by operators. This allows the detection device to adapt to various welding positions, geometries, and access conditions while maintaining sufficient stability during operation through controlled handheld positioning.
2Measurement precision
If a separate controller with high computing power is used, then the detection accuracy is improved, but the device complexity and cost increase
Solution Approach 1:
The patent integrates the processing unit directly into the handheld detection device, combining the sensor, processor, and power supply into a single unified system. This eliminates the need for a separate external controller and reduces system complexity while maintaining sufficient processing capability for real-time defect detection.
Solution Approach 2:
The patent uses simplified processing algorithms and pre-stored reference data to achieve accurate defect detection without requiring high-performance computing hardware. By using pattern recognition based on stored reference profiles rather than complex real-time computation, the system achieves detection accuracy with reduced computational demands.
3Duration of action of stationary object
If an external power source is required, then the detection device can operate continuously, but the mobility and accessibility are restricted
Solution Approach 1:
The patent incorporates an internal power supply (rechargeable battery) directly into the handheld detection device, making it self-powered and independent of external power sources. This enables complete mobility and accessibility to remote or hard-to-reach welding locations while providing sufficient operating duration through the integrated battery system.
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 real-time, accurate, and versatile weld defect detection across various surfaces and geometries, reducing complexity, cost, and enhancing mobility with wireless communication and data sharing.
Implementation Method 1
projects a beam laser light on the weld surface that is being inspected using a laser emitter
Implementation Method 2
A processor incorporated within the handheld device receives the projected beam of thin laser light from a laser receiving sensor
Data Source
AI summary
Provided is a handheld device and a method for detecting weld defects on a weld surface. The handheld device projects a thin beam laser light on the weld surface using a laser emitter. A processor receives the projected thin beam laser light from a laser receiving sensor, which indicates captured contours of the weld surface. The captured contours are processed to filter laser lines and extract contours. The extracted contours are utilized to classify a type of weld surface such as, surface joints, butt joints, corner joints, and tee joints. The processor, upon classifying, automatically adjusts angle and position of the laser light to be projected on the weld surface and detects deviation patterns by employing an ensemble of a laser line extraction process and a pixel width measurement process. The processor determines the detected deviation patterns as one or more defects on the weld surface that is being inspected.