Omni-Directional Weld Seam Sensor for Curved and 90° Weld Tracking
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Solution Overview
Problem
Existing weld seam tracking laser vision sensors face issues such as collision with workpieces and limitations in detecting complex curve weld seams, particularly curved and 90°-deflection angle weld seams, leading to interruptions in the welding process.
Innovation Solution
An omni-directional weld seam tracking laser vision sensor is designed with a cylindrical structure that surrounds the welding gun, incorporating at least three cameras and a laser to form a 360° enclosed laser stripe image, allowing real-time detection of complex weld seams without direction adjustments, and an image processing module to concatenate camera images for continuous tracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a linear laser sensor is used for weld seam tracking, then the sensor can detect straight weld seams, but the sensor volume is large and easily collides with the workpiece
Solution Approach 1:
The sensor is nested within a cylindrical protective housing that surrounds the welding gun. The housing contains the laser emitter and camera components, positioning them within a compact cylindrical structure that fits around the welding gun without protruding significantly, thereby reducing collision risk while maintaining sensor functionality
Solution Approach 2:
The sensor arrangement transitions from a linear configuration to a three-dimensional cylindrical arrangement. The laser and camera are positioned at specific angles around the welding gun within the cylindrical housing, enabling omni-directional detection capability while maintaining a compact overall volume that reduces collision probability
2Adaptability or versatility
If a linear laser sensor is placed at the front or rear end of the welding gun, then the setup is simple, but the sensor can only track long and straight weld seams and cannot handle complex spatial curves
Solution Approach 1:
The detection function is segmented into multiple directional components. The cylindrical housing contains the laser and camera arranged at different angular positions, with each segment detecting weld seams in specific directions. This segmentation enables the system to handle complex spatial curves by combining information from multiple detection zones
Solution Approach 2:
The cylindrical sensor housing serves multiple functions simultaneously: it protects the internal components, provides a compact mounting structure, enables omni-directional detection, and accommodates the laser and camera in an integrated arrangement. This multi-functionality allows the sensor to track various weld seam types including straight lines, curves, and 90° deflection angles without requiring complex external support structures
3Productivity
If the welding gun and sensor rotate to track complex spatial curves, then the weld seam can be tracked, but blind areas occur at deflection angles and welding must be stopped for adjustment
Solution Approach 1:
The sensor is pre-positioned in a cylindrical housing that surrounds the welding gun, with the laser and camera arranged to provide overlapping detection fields in all directions around the welding area. This preliminary arrangement ensures that weld seams at any orientation, including 90° deflection angles, are continuously detectable without creating blind areas that would require welding interruption
Solution Approach 2:
The omni-directional sensor arrangement within the cylindrical housing enables continuous detection of the weld seam throughout the entire welding process. The overlapping detection zones and multi-angular positioning ensure that no blind areas occur during direction changes, allowing the welding operation to proceed continuously without stopping for sensor repositioning or adjustment
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 sensor enables continuous welding of complex weld seams by avoiding collisions and blind areas, improving welding efficiency and quality through omni-directional detection and accurate automatic control.
Implementation Method 1
a laser and at least three cameras are arranged around a welding gun... a laser closed stripe image surrounding a working area of a welding gun can be collected in real time
Implementation Method 2
the cameras surround the welding gun mounting hole and are uniformly distributed in a peripheral direction, and the cameras are configured to capture a laser closed stripe image formed by a laser beam emitted by the laser
Implementation Method 3
a filter is arranged at the other end of the cylinder, and a through hole is provided on the filter... The filter is located at a front end of the camera, the wavelength of the light allowed to be passed through is the same as the wavelength of the laser beam emitted by the laser
Data Source
AI summary
The present disclosure discloses an omni-directional weld seam tracking laser vision sensor, a sensing method, and a welding apparatus, relating to the field of welding automation. The sensor includes a sensor housing, a mounting bracket, a filter, a laser, and at least three cameras. The cameras surround a welding gun mounting hole and are uniformly distributed in a peripheral direction; the cameras are configured to capture a laser-closed stripe image formed by a laser beam emitted by the laser; the filter is positioned at the front end of the camera, the wavelength of the light allowed to be passed through is the same as the wavelength of the laser beam emitted by the laser; and the sensor further includes an image processing module arranged in the sensor housing, configured to connect the camera, to receive image information captured by the camera.