Laser Welding State Detection Using Thermal and Reflected Light
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Solution Overview
Problem
Existing methods for detecting welding defects, such as recesses, are inadequate for various welding processes and materials, particularly when welding a metal plate with multiple metal plates, as they fail to account for variations in signal levels due to different welding methods and materials.
Innovation Solution
A method and device that measure the intensity of thermal radiation light and reflected light during laser welding to detect welding states by comparing signal intensities against reference values, determining the presence of recesses based on decreases in thermal radiation light intensity and increases in reflected light intensity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing detection methods are used for laser welding, then detection can be performed, but detection precision deteriorates when welding metal plates with multiple materials due to signal level variations
Solution Approach 1:
The patent dynamically adjusts detection parameters including threshold values and reference signal levels based on the specific welding method and materials being used. By changing these parameters according to the welding conditions, the system maintains high detection precision across different material combinations and welding processes while adapting to signal level variations caused by different materials.
2Reliability
If threshold-based detection is used, then detection simplicity is maintained, but detection reliability decreases when signal levels vary due to different welding methods and materials
Solution Approach 1:
The system employs feedback mechanisms where reference signal levels are established based on actual welding conditions, and threshold values are dynamically adjusted according to detected signal variations. This feedback loop continuously adapts the detection parameters to match the current welding state, ensuring reliable detection without requiring complex manual calibration for each welding scenario.
Solution Approach 2:
The patent performs preliminary detection to establish reference signal levels and appropriate threshold values before conducting the main welding defect detection. By pre-calibrating the detection parameters based on the specific welding method and materials, the system ensures reliable detection while avoiding the need for complex real-time adjustments during actual welding monitoring.
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
Accurately detects welding defects like recesses with high precision by analyzing signal intensity changes, enabling efficient detection of welding states in diverse welding scenarios.
Implementation Method 1
a first signal intensity indicating an intensity of thermal radiation light generated from a portion irradiated with laser light
Implementation Method 2
a second signal intensity indicating an intensity of reflected light reflected from the portion irradiated with the laser light
Data Source
AI summary
A detection method of the present disclosure is a method for detecting a welding state executed by a processor, the method including acquiring a first signal intensity indicating an intensity of thermal radiation light generated from a portion irradiated with laser light and a second signal intensity indicating an intensity of reflected light reflected from the portion irradiated with the laser light, and detecting a welding state of the portion irradiated with the laser light based on the first signal intensity and the second signal intensity, in which the detecting the welding state determines whether or not the first signal intensity is less than or equal to a first reference signal intensity of thermal radiation light and the second signal intensity is greater than a second reference signal intensity of reflected light.