Multi-Wavelength Image Comparison for Laser Welding Mode Determination
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing welding technologies, such as arc welding and laser beam welding, face challenges in objectively determining the welding mode as it changes over time, leading to inconsistencies in welding quality and reliability, particularly in hermetically sealing battery components like metal covers and cases.
Innovation Solution
A welding mode determination device and method that utilize image capturing units in infrared and short wavelength visible light regions to compare light emitting images, allowing for objective determination of the welding mode by analyzing size and luminance differences between images captured in these regions, thereby controlling the energy intensity of the laser beam for precise welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If welding mode determination is performed using single-wavelength image capture, then device complexity is reduced, but measurement precision and reliability of welding mode determination deteriorate
Solution Approach 1:
The image capturing system is segmented into multiple independent image capturing units, each dedicated to capturing images at specific wavelengths. This segmentation allows each unit to specialize in detecting particular welding characteristics (e.g., arc plasma, weld pool) without interference, thereby improving measurement precision while keeping individual unit complexity manageable
Solution Approach 2:
The system transitions from single-wavelength detection to multi-wavelength detection by adding the wavelength dimension to the image capturing process. This dimensional expansion enables simultaneous observation of different welding phenomena (arc, weld pool, vaporization) that occur at different wavelengths, significantly improving welding mode determination accuracy
2Measurement precision
If multiple image capturing units with different wavelength filters are used, then welding mode determination accuracy is improved, but device complexity increases
Solution Approach 1:
Multiple image capturing units are designed with universal functionality to capture images of the same welding area but at different wavelengths. Each unit serves multiple purposes: detecting arc plasma, monitoring weld pool, and identifying welding mode. This multi-functionality approach improves measurement precision without proportionally increasing device complexity
Solution Approach 2:
The system exploits the wavelength dimension by deploying multiple image capturing units with different band-pass filters. This allows simultaneous multi-wavelength observation of welding processes, enabling accurate differentiation between welding modes (heat conduction, keyhole, transition) through comparative analysis of light emission characteristics at various wavelengths
3Reliability
If real-time welding mode monitoring is implemented, then welding quality and reliability are improved, but loss of time for processing and analysis increases
Solution Approach 1:
The system performs preliminary action by capturing images at multiple wavelengths simultaneously during the welding process, rather than sequentially. This simultaneous multi-wavelength image capture provides real-time data for immediate welding mode determination, improving reliability without significant time loss
Solution Approach 2:
The system implements feedback by continuously monitoring welding images at multiple wavelengths and using this real-time information to determine welding mode. The feedback loop enables dynamic adjustment of welding parameters if mode deviation is detected, ensuring welding quality and reliability while maintaining real-time operation through efficient image processing algorithms
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 accurate and objective determination of the welding mode, ensuring appropriate strength and hermetic sealing of battery components, maintaining reliability even under conditions like vibration and thermal loads, by comparing light emitting images in infrared and visible light wavelengths.
Implementation Method 1
an image in an infrared wavelength region and an image in a short wavelength region of visible light are obtained from a laser irradiation area
Implementation Method 2
a light emitting image is extracted from the image in the infrared wavelength region and a light emitting image is extracted from the image in the short wavelength region of visible light
Data Source
AI summary
A welding mode determination device that determines a welding mode when laser beam welding is performed includes an obtaining unit that obtains an image in an infrared wavelength region and an image in a short wavelength region of visible light from a laser irradiation area and its vicinity. An extraction unit extracts a light emitting image from the image in the infrared wavelength region and a light emitting image from the image in the short wavelength region of visible light. A determination unit compares the light emitting image of the image in the infrared wavelength region and the light emitting image of the image in the short wavelength region of visible light and determines the welding mode when the laser beam welding is performed based on a comparison result.