Joining Seam Inspection With Fixed-Camera Image Realignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for simultaneously depositing and controlling material beads on industrial parts are complex, limiting the control device's performance and requiring intricate camera movements, which are slow and impractical.
Innovation Solution
A control method and system that uses a vision machine on a robotic arm or mobile support to dynamically realign images with reference data, compensating for dimensional and positional drifts, and generating corrective actions for precise bead placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the camera follows the movement of the bead deposition device to perform dimensional control, then the inspection can be performed during the same operation, but the camera speed is limited by the deposition device speed and the tool becomes very complex
Solution Approach 1:
Instead of moving the camera with the deposition device, the patent inverts the approach by keeping the camera fixed and moving the part (or the deposition device) relative to the camera. This allows the camera to remain stationary while still capturing images of the bead at different positions, thereby reducing tool complexity while maintaining inspection capability.
Solution Approach 2:
The patent introduces an intermediary coordinate system transformation mechanism that maps images taken from a fixed camera position to the moving part's coordinate system. This intermediary transformation allows the fixed camera to effectively inspect moving beads without requiring the camera to physically follow the deposition device.
2Reliability
If the camera follows the movement of the bead deposition device, then simultaneous deposition and control can be performed, but the camera is not positioned in an ideal location for visual quality checking
Solution Approach 1:
The patent replaces the mechanical coupling between the camera and deposition device with a computational solution. By using coordinate transformation algorithms and image processing, the system achieves accurate measurement without the camera being mechanically attached to or moving with the deposition device, thereby optimizing both reliability and measurement precision.
Solution Approach 2:
The patent transitions from a single moving camera perspective to a multi-dimensional solution involving fixed camera positions combined with coordinate system transformations. This allows images to be reconstructed and analyzed in the part's reference frame, achieving ideal inspection positioning without mechanical movement of the camera.
3Measurement precision
If multiple fixed reference marks are used on the part, then inspection accuracy is improved, but the part design becomes more complex
Solution Approach 1:
The patent applies reference marks selectively at specific critical locations on the part where they are most needed for accurate measurement and alignment, rather than uniformly distributing them across the entire part. This localized approach maintains inspection accuracy while minimizing the number of marks required and reducing part design complexity.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a method for controlling physical parameters relating to a bead deposited on a part la, consisting of defining the parameters to be controlled in order to detect defects in the bead, choosing at least three fixed reference points lb on the part la to define the ideal location of the bead on the part relative to the fixed reference points lb, using a movement device to generate a relative displacement between the part and the vision machine, using at least one vision machine to record a succession of images of the bead, using a display tool 6 of the tablet type connected to a specific database 3 and allowing an operator to follow the progress of the control operations, comparing the images read and recorded of the bead to ideal images using algorithms loaded into the specific database 3, and identifying and displaying the defects of the bead on the display tool 6 and validating or not said defects.