Automated Laser Welder Alignment via Camera Vision
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Solution Overview
Problem
The manual alignment and positioning of products in laser welding processes for medical devices, such as balloon catheters, are time-consuming and introduce variability, leading to increased manufacturing time and product reprocessing.
Innovation Solution
An automated laser welder alignment system that uses a camera to capture visualization data and a controller to translate this data into positioning instructions for the laser welder, enabling the system to automatically position and verify the alignment of products within defined tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual alignment and positioning is used, then the operator can visually verify positioning, but operator time is consumed and variability is introduced
Solution Approach 1:
The patent replaces the manual mechanical alignment process with an automated optical measurement system. A camera captures images of the product, and image processing algorithms automatically determine positioning and alignment, substituting human visual inspection and manual adjustment with automated vision-based measurement and control.
Solution Approach 2:
The system enables self-alignment by having the product's own features (such as geometric characteristics visible in camera images) serve as reference points for positioning. The image processing system extracts positioning information directly from the product imagery without requiring external fixtures or manual intervention, allowing the product to essentially align itself through automated detection.
2Ease of operation
If manual alignment is used, then positioning can be adjusted, but process bottlenecks occur and manufacturing time increases
Solution Approach 1:
The patent replaces manual adjustment operations with automated image-based positioning. The system captures product images, processes them to determine optimal positioning, and automatically adjusts the product location, eliminating the time-consuming manual adjustment phase while preserving the ability to achieve precise positioning.
Solution Approach 2:
The system performs preliminary positioning based on image analysis before the actual welding or manufacturing operation. By determining the correct position in advance through image processing and preparing the positioning instructions beforehand, the system eliminates delays during the manufacturing cycle and ensures ready-to-execute positioning commands.
3Productivity
If automated alignment is implemented, then productivity increases, but system complexity increases
Solution Approach 1:
The patent introduces a camera as an intermediary device between the product and the positioning system. The camera captures visual information that serves as input for image processing algorithms, which then generate positioning instructions. This intermediary approach automates the alignment process while keeping the added complexity concentrated in the sensing and processing layer rather than requiring complex mechanical alignment mechanisms.
4Manufacturing precision
If visual verification is performed manually, then positioning accuracy can be confirmed, but operator variability affects consistency
Solution Approach 1:
The patent replaces human visual verification with automated image processing. The system uses algorithms to consistently analyze product images and determine positioning accuracy, eliminating operator-to-operator variability and ensuring uniform application of positioning criteria across all products, thereby improving both precision and reliability.
Solution Approach 2:
The system implements automated feedback by capturing product images, analyzing positioning accuracy through image processing, and using the results to verify or adjust positioning before manufacturing operations. This closed-loop feedback mechanism ensures consistent quality verification without human variability while maintaining high positioning precision.
Data Source
AI summary
A laser welder alignment system includes a laser welder, a camera associated with the laser welder configured to capture images of a loaded product within the laser welder, and a controller in communicative association with the laser welder and the camera. The controller receives visualization data from the camera and, based on the visualization data, forms and sends positioning instructions to the laser welder instructing the laser welder so as to position the loaded product at a proper weld start. The laser welder alignment system also verifies proper positioning of the loaded product within the laser welder, and verifies proper rotation of the loaded component by determining whether the rotating product has a wobble that exceeds a pre-defined wobble tolerance.