Optical Weld Seam Geometry Detection Without Precise Sensor Alignment
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Solution Overview
Problem
Manual visual assessment of weld seam geometry in plastic butt welds is time-consuming and expensive, and existing automated methods require precise alignment of sensors, which is complex and often limited to immediate post-welding inspections.
Innovation Solution
A method and device using an optical sensor with automatic positioning along a sensor axis to find the optimal measurement position for evaluating weld seam geometry, allowing for quick and accurate quality assessment without the need for precise sensor alignment, utilizing a combination of manual rough positioning and autonomous movement to record and evaluate weld seam dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual visual assessment is used to evaluate weld seam quality, then the assessment can be performed by a competent specialist using standards and guidelines, but the process is very time-consuming and expensive
Solution Approach 1:
The patent replaces the manual mechanical visual assessment system with an automated optical measurement system. A sensor automatically measures the weld seam geometry at multiple positions along the pipe, eliminating the need for manual visual inspection by specialists. This substitution of mechanical/manual processes with automated optical measurement directly resolves the contradiction by maintaining reliable quality assessment while dramatically reducing assessment time.
2Reliability
If ultrasonic sensors are used to test weld fusion, then internal pipe wall fusion can be detected, but the test requires very precise positioning and long set-up time
Solution Approach 1:
The patent replaces the complex ultrasonic sensor positioning system with a simplified optical sensor system. Instead of requiring precise mechanical positioning of ultrasonic sensors to detect internal fusion, the invention uses optical sensors that can be roughly manually positioned and then automatically move to measurement positions. This substitution eliminates the complex positioning requirements while maintaining reliable quality detection.
Solution Approach 2:
The patent introduces dynamic automatic positioning of the optical sensor along the pipe. The sensor is mounted on a carrier device with a drive mechanism that automatically moves the sensor to optimal measurement positions based on recorded data. This dynamic adaptation allows the system to find and use the best measurement positions without requiring precise initial alignment, thereby reducing device complexity while maintaining detection reliability.
3Measurement precision
If precise alignment of the weld seam with the sensor is required, then accurate weld seam geometry detection can be achieved, but the alignment process is complex and time-consuming
Solution Approach 1:
The patent implements dynamic automatic positioning of the sensor along the pipe using a carrier device with drive mechanisms. The sensor automatically moves to optimal measurement positions determined by preliminary recordings, eliminating the need for manual precise alignment. This dynamic system maintains high measurement precision while dramatically improving ease of operation, as the sensor self-adjusts to the correct positions automatically.
Solution Approach 2:
The patent performs preliminary measurements at multiple positions along the pipe before the final quality assessment. These preliminary recordings are used to determine the optimal measurement positions and orientations. By performing this preliminary action, the system establishes the best measurement configuration in advance, which then guides the final high-precision measurement without requiring complex real-time alignment during the actual quality assessment.
4Reliability
If the welding bead is removed for manual check, then the weld seam quality can be assessed, but the inspection process becomes more complex and time-consuming
Solution Approach 1:
The patent replaces the mechanical process of removing and manually checking the welding bead with an automated optical measurement system. The sensor non-contactively measures the weld seam geometry directly on the welded joint without requiring any material removal or complex manual inspection procedures. This substitution maintains reliable quality evaluation while dramatically simplifying the inspection process and eliminating destructive or semi-destructive methods.
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
Enables rapid and reliable evaluation of weld seam quality, reducing assessment time to a few seconds and eliminating the need for precise sensor alignment, allowing for both immediate and subsequent inspections.
Implementation Method 1
an optical sensor... recording the visible weld seam geometry... at each measurement position approached
Data Source
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AI summary
Method and apparatus for detecting the weld geometry of a plastic butt weld between pipeline components, preferably plastic pipes, comprising the following steps: • coarse, manual positioning of an optical sensor opposite a butt weld between pipeline components, preferably plastic pipes, preferably at the pipe's outer diameter, wherein the sensor alignment is approximately perpendicular to the pipe's central axis, • automatic approach of the sensor to measuring positions along or around a sensor axis, • detection of the visible weld geometry or• Acquisition of data by means of a sensor in each approached measurement position, • determination of the optimal measurement position from the acquired data, preferably by means of an algorithm, • automatic approach of the sensor to the optimal measurement position along or around the sensor axis, • acquisition of the weld seam geometry to determine the quality of the weld seam, • evaluation and assessment of the measurement of the acquired weld seam geometry at the optimized measurement position.