Laser Microphone Anomaly Detection for Laser Welding
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Solution Overview
Problem
Existing anomaly detection techniques in welding processes are prone to errors due to noise interference, particularly when detecting anomalies in welded parts based on audible sounds during laser welding.
Innovation Solution
An anomaly detection device that utilizes a laser microphone to acquire and analyze inaudible sounds generated during laser welding, focusing on changes in sound pressure within specific frequency bands (100 kHz to 200 kHz) to enhance detection accuracy, unaffected by ambient noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If audible sound is used for anomaly detection, then detection method is simple, but detection accuracy deteriorates due to noise interference
Solution Approach 1:
The patent changes the frequency parameter of sound detection from audible range to inaudible range (ultrasonic waves). By detecting anomalies through inaudible sound frequency changes rather than audible sound, the system maintains operational simplicity while eliminating noise interference that affects audible sound detection, thereby improving detection accuracy.
2Measurement precision
If inaudible sound is used for anomaly detection, then detection accuracy improves, but device complexity increases
Solution Approach 1:
The patent replaces traditional acoustic measurement devices with a laser-based measurement system. The laser microphone measures vibrations of the welded part surface caused by inaudible sounds, substituting mechanical sound collection with optical measurement. This approach achieves high detection accuracy through inaudible sound while avoiding the complexity of specialized ultrasonic sensors or microphones.
3Device complexity
If traditional sound collection method is used, then device structure is simple, but noise interference increases
Solution Approach 1:
The patent introduces a laser beam as an intermediary between the welded part and the measurement system. The laser beam reflects off the welded part surface, and variations in the reflected light caused by surface vibrations are detected. This intermediary approach allows noise-free measurement of inaudible sounds while maintaining relatively simple device structure, as the laser acts as a non-contact mediator that doesn't require complex acoustic coupling.
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
The device accurately detects anomalies in welded parts by minimizing noise interference, improving detection accuracy and enabling notifications when anomalies occur, even in challenging environments like high temperatures or electromagnetic fields.
Implementation Method 1
a sound which is generated at a welded part during laser welding and is collected by a sound collector
Data Source
AI summary
An anomaly detection device includes: a sound collector that acquires a sound which is generated at a welded part during laser welding and is collected by the sound collector; and a detector that detects an anomaly in the welded part based on a change in an inaudible sound included in the sound acquired by the sound collector.