Optical Weld Bead Inspection for Complex Pipe Joints
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Solution Overview
Problem
Conventional ultrasonic weld bead inspection devices are bulky, expensive, and difficult to manage, requiring complex equipment and expertise to analyze ultrasound images, making it challenging for non-experts to assess welding quality accurately and efficiently, especially in complex pipe systems.
Innovation Solution
A compact weld bead inspection device that uses imaging technology to capture and analyze digital data of weld beads on pipe surfaces without ultrasonic waves, allowing for easy sharing of results via communication networks and enabling non-experts to determine defects through close-up imaging, with features like a withdrawal supporting unit for stable attachment and a bead tracking guide for navigating complex pipe geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional ultrasonic weld bead inspection devices are used, then welding quality inspection can be performed, but the devices are bulky, expensive, and difficult to manage
Solution Approach 1:
The patent replaces the conventional ultrasonic wave-based inspection system with an optical imaging system. Instead of using ultrasonic projectors and complex signal conversion devices, the invention uses an imaging unit with light sources to capture images of weld beads directly, eliminating the need for bulky ultrasonic equipment while maintaining inspection capability
Solution Approach 2:
The patent creates visual copies (images) of the weld bead surfaces using an imaging unit. By capturing and analyzing images of the weld bead geometry and surface characteristics, the system reproduces the inspection function without requiring physical contact or complex ultrasonic transducers, thereby simplifying the device structure
2Measurement precision
If ultrasonic waves are used for inspection, then welding quality can be measured, but expensive components and complex analysis methods are required
Solution Approach 1:
The patent substitutes the expensive ultrasonic measurement system with a cost-effective optical imaging system. The imaging unit captures weld bead characteristics using light, and standard image processing techniques analyze the data, eliminating the need for costly ultrasonic projectors and specialized signal analysis equipment
Solution Approach 2:
The patent changes the measurement parameter from ultrasonic wave properties to optical image properties. By capturing geometric and surface characteristics of weld beads through imaging, the system achieves measurement precision using conventional, cost-effective imaging components rather than expensive ultrasonic equipment
3Reliability
If conventional ultrasonic imaging is used, then weld bead inspection can be performed, but the results are not clear and difficult for non-experts to recognize
Solution Approach 1:
The patent creates visual copies (photographs) of the weld bead surfaces that directly represent the actual weld appearance. These images are intuitive and can be easily recognized by non-experts, unlike abstract ultrasonic waveforms that require specialized training to interpret
Solution Approach 2:
The patent uses color imaging to capture and display weld bead characteristics. The visual information presented through color photographs makes it easy for users to identify weld quality issues without requiring expert knowledge of ultrasonic signal interpretation
4Measurement precision
If ultrasonic projectors and signal conversion devices are used, then welding quality can be measured, but the devices are bulky and heavy
Solution Approach 1:
The patent replaces heavy ultrasonic projectors and signal conversion devices with a lightweight imaging unit. The imaging system uses light sources and sensors that are significantly lighter than ultrasonic equipment, while achieving the measurement function through optical rather than acoustic means
Data Source
AI summary
The present invention relates to a weld bead inspection device that inspects welding quality by measuring the state of beads formed at a welding part of a metallic or non-metallic pipe, or the like, and more specifically, to a weld bead inspection device that more efficiently inspects a welding part joined by a method such as thermal fusion for connection between pipes or connection between a pipe and a fitting. The weld bead inspection device includes a housing unit that forms an appearance; an imaging unit that images shapes of the weld beads in an inner space that is open downward from a middle inner side of the housing unit; a control unit that is provided in the housing unit to store image data captured by the imaging unit or to calculate external shapes of the weld beads for determining welding quality on the basis of the image data.