Vision-Guided Laser Welding With Temporary Camera Parameter Reset
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Solution Overview
Problem
Arbitrary manipulation of process variables in laser welding equipment can lead to product defects and equipment failures, and temporary adjustments can cause further issues if not managed properly.
Innovation Solution
A laser welding process system that includes a vision camera for recognizing welding locations, a laser scan head for performing welds, and a controller for temporarily changing and resetting initial set values of the vision camera based on recognition rates, with modes for operator and manager intervention to ensure reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the vision camera's initial set value is arbitrarily changed to solve temporary recognition problems, then the welding location recognition may be improved temporarily, but it causes product defects and equipment failures due to improper variable manipulation
Solution Approach 1:
The system dynamically adjusts the vision camera's set values based on real-time recognition needs. When recognition fails, the controller temporarily modifies the initial set value to enable welding, then restores it afterward. This dynamic adjustment mechanism allows the system to adapt to temporary recognition issues without permanently altering configuration parameters, thus maintaining reliability while improving recognition accuracy when needed.
Solution Approach 2:
The controller changes the vision camera's set values (parameters) temporarily to resolve recognition problems. Instead of arbitrarily manipulating parameters, the system systematically adjusts them under controller management, performs the necessary welding operations, and then restores the original parameters. This controlled parameter change approach ensures that temporary adjustments do not lead to cumulative errors or equipment failures.
2Measurement precision
If the vision camera's initial set value is permanently modified to improve recognition, then recognition accuracy is improved, but it causes bigger problems in production equipment due to improper value propagation to subsequent processes
Solution Approach 1:
The system uses dynamic parameter adjustment rather than permanent modification. The controller temporarily changes the vision camera's initial set value only when recognition fails, performs the welding operation, and then restores the original value. This ensures that parameter changes are localized to specific problem instances and do not propagate harmful effects to subsequent production processes.
Solution Approach 2:
The parameter adjustment is segmented into temporary, isolated instances rather than a permanent global change. Each set value modification is confined to a specific recognition failure event, allowing the system to address individual problems without affecting the overall production process configuration. This segmentation prevents harmful propagation of modified values to subsequent processes.
3Productivity
If the vision camera continuously fails to recognize welding locations, then productivity decreases due to repeated interruptions, but arbitrary parameter changes to fix the problem lead to equipment failures
Solution Approach 1:
The system implements a feedback mechanism where the controller monitors vision camera recognition results in real-time. When recognition fails, the controller receives feedback and automatically adjusts the set value, performs welding, and restores the original value. This closed-loop feedback system allows the equipment to self-correct recognition failures without manual intervention, maintaining high productivity while preventing the harmful effects of arbitrary parameter manipulation through automated, controlled adjustments.
Solution Approach 2:
The system provides self-service by automatically detecting recognition failures and resolving them through controlled parameter adjustment. The controller autonomously manages the temporary set value changes, welding operations, and parameter restoration without requiring external intervention. This self-service capability maintains productivity by quickly resolving recognition issues while ensuring reliability through systematic, automated parameter management.
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 enhances the reliability and precision of the welding process, improves productivity, and stabilizes automation, effectively addressing the challenges of variable manipulation and equipment operation.
Implementation Method 1
a laser scan head for performing a welding process on the material through a laser light source
Implementation Method 2
a vision camera for recognizing a welding location of a material deposited on a welding station
Data Source
AI summary
Provided is a laser welding process system including a vision camera for recognizing a welding location of a material deposited on a welding station; a laser scan head for performing a welding process on the material through a laser light source when the welding location of the material is recognized by the vision camera; and a controller for temporarily changing an initial set value of the vision camera to perform the welding process when the welding location of the material is not recognized by the vision camera and next making a return to the initial set value, and for modifying the initial set value of the vision camera when the number of times that the welding location is not recognized exceeds a preset number.