Laser Joint Surface Inspection Using Segmented Image Strips
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Solution Overview
Problem
Conventional methods for quality control of laser-beam hard soldering and laser-beam welding connections in the automobile industry face challenges in detecting surface irregularities, such as holes and splashed material, which can lead to uneven surfaces and reduced joint strength, requiring improved detection systems to prevent frequent stopping of the joining process.
Innovation Solution
A method involving photographic recording and image processing techniques, where image strips are created perpendicular to the connecting region, transformed into brightness or color regions, and assessed for anomalies, allowing for real-time monitoring and adjustment during production, with overlapping image strips providing redundancy and normalization to account for varying brightness and surface differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional optical systems are used to monitor the production process, then surface quality can be assessed, but the detection rate is insufficient leading to frequent stopping of the joining method
Solution Approach 1:
The image recording is divided into multiple image strips arranged vertically with respect to the longitudinal orientation of the connecting region. This segmentation allows for more focused and precise analysis of specific regions, improving detection rate without requiring complete system stops for comprehensive inspection.
Solution Approach 2:
Instead of analyzing the entire image recording in detail, the method applies assessment to selected image strips that are most relevant to detecting surface irregularities. This partial action approach maintains high detection rates while minimizing interruptions to the joining process.
2Measurement precision
If image processing is performed on the entire recording, then comprehensive quality assessment is achieved, but computerized calculation outlay becomes excessive
Solution Approach 1:
The recording is divided into multiple image strips, and only these specific strips are subjected to detailed assessment. This segmentation reduces the total number of pixels and regions requiring computational analysis, significantly lowering computerized calculation outlay while maintaining assessment accuracy for critical areas.
Solution Approach 2:
The method extracts and analyzes only the relevant image strips that contain the connecting region information, rather than processing the entire recording. This extraction approach reduces computational burden while preserving the essential quality assessment capabilities.
3Measurement precision
If image strips are arranged vertically perpendicular to the connecting region, then detection accuracy is improved, but the complexity of image processing increases
Solution Approach 1:
The vertical arrangement of image strips creates a segmented view of the connecting region, improving detection accuracy by focusing on specific vertical sections. The segmentation is implemented through simple geometric division rather than complex algorithms, balancing accuracy improvement with processing simplicity.
Solution Approach 2:
Different image strips can be assessed with different levels of detail based on their local characteristics. This local quality approach allows the system to maintain high detection accuracy where needed while reducing processing complexity in less critical areas.
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
This approach enables efficient detection of surface irregularities and anomalies in real-time, reducing false positives and improving the accuracy of surface quality assessment, allowing for immediate reprocessing of irregularities and enhancing the reliability of the joining process.
Implementation Method 1
a laser beam is guided along the joining location while melting an auxiliary material, for example a copper-silicon wire
Implementation Method 2
melting an auxiliary material
Implementation Method 3
optical systems which are used to monitor the production process and to appraise the surface quality
Data Source
AI summary
A method for checking a connection region formed during a joining process of at least two metal components via a laser. The method includes producing a photographic recording of the connection region being formed, transforming the photographic recording, creating at least two image strips in the photographic recording, and assessing the at least two image strips. An apparatus for carrying out the method is further provided.