Multi-Wavelength Vision Inspection for Weld Occlusion and Reflectivity
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Solution Overview
Problem
Existing vision inspection systems face challenges in capturing high-quality images of welds and surface features due to issues such as high surface gradients, occlusion, shadowing, and varying material reflectivity, which result in missing data and poor image quality.
Innovation Solution
A vision inspection system utilizing two vision sensing assemblies with light sources emitting different wavelengths, allowing sensors to detect and compensate for visibility and reflectivity differences, and a control module to combine images based on material type and relative motion, generating composite images with improved clarity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single vision sensing assembly with one wavelength light source is used, then the device complexity is low, but the image quality and measurement precision deteriorate due to occlusion, shadowing, and varying material reflectivity
Solution Approach 1:
The vision inspection system is segmented into multiple independent vision sensing assemblies, each equipped with light sources of different wavelengths. This segmentation allows each assembly to target specific material reflectivity characteristics, thereby improving overall measurement precision without requiring a single overly complex system to handle all material variations simultaneously.
Solution Approach 2:
The system changes the wavelength parameter of the light source across different vision sensing assemblies. By using light sources with different wavelengths (e.g., blue, green, red, infrared), the system adapts to varying material reflectivity properties, enabling accurate inspection of diverse materials including highly reflective surfaces without increasing individual assembly complexity.
2Reliability
If multiple vision sensing assemblies with different wavelengths are used, then visibility and reflectivity challenges are addressed, but the device complexity increases
Solution Approach 1:
Each vision sensing assembly is designed as a universal module capable of inspecting multiple material types by incorporating light sources of different wavelengths. This multi-functionality allows the same hardware architecture to reliably handle varying reflectivity challenges across different materials, improving reliability without proportionally increasing device complexity through repeated specialized designs.
Solution Approach 2:
The control module serves as an intermediary that coordinates multiple vision sensing assemblies, managing their operation and synthesizing their outputs. This intermediary component enables the system to handle complex multi-wavelength inspection tasks while maintaining manageable overall system complexity through centralized control and coordination.
3Measurement precision
If images from multiple sensors are combined, then occlusion and shadowing are overcome, but the processing time and loss of time increase
Solution Approach 1:
The control module is pre-configured with algorithms to synchronize and combine images from multiple vision sensing assemblies in real-time. By preparing the image processing pipeline in advance and using predetermined combination strategies, the system minimizes processing time while still achieving high-quality composite images that overcome occlusion and shadowing effects.
Solution Approach 2:
The system maintains continuous operation by processing and combining images from multiple sensors simultaneously rather than sequentially. This continuous parallel processing ensures that the useful action of image acquisition and combination occurs without interruption, minimizing time loss while generating high-quality composite images that address occlusion and shadowing.
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 system effectively addresses visibility and reflectivity challenges by combining images from sensors with different wavelength filters, resulting in high-quality 3D surface depth maps that overcome occlusion and material-specific reflectivity issues.
Implementation Method 1
a first sensor configured to detect the light having the first wavelength reflected by the workpiece
Data Source
AI summary
A system includes a station to support a workpiece having one or more welds and/or surface features, and first and second vision sensing assemblies. The first assembly is configured to illuminate the workpiece and generate an image of the one or more welds and/or surface features. The first assembly includes a first light source configured to emit light having a first wavelength and a first sensor configured to detect the light having the first wavelength reflected by the workpiece. The second assembly is configured to illuminate the workpiece and generate an image of the one or more welds and/or surface features. The second assembly includes a second light source configured to emit light having a second wavelength and a second sensor configured to detect the light having the second wavelength reflected by the workpiece. Other example systems and methods are also disclosed.