Portable Spatter Counting via Image Binarization in Welding

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Solution Overview

Problem

Conventional spatter counting methods require large-scale and expensive equipment, making them costly and impractical for portable use, especially in welding narrow gaps, and there is a need for a simpler, cost-effective technique to accurately count spatters during welding.

Innovation Solution

A spatter counting method using a portable terminal device with an image capturing unit that captures moving images of the welding area, performs binarization processing, and counts spatters based on threshold values for black and white gradation and size, with adjustable shutter speed and ISO sensitivity, allowing for accurate spatter detection and display of results.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional spatter recognition methods are used, then measurement accuracy is improved, but device complexity and cost increase

Engineering Contradiction:

Improvespatter measurement accuracyVSAvoidequipment scale

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent uses a standard camera to capture images of spatters, creating a visual copy that can be analyzed through image processing. This replaces the need for complex high-speed cameras while maintaining measurement capability through photographic documentation and digital analysis

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces mechanical/high-speed imaging systems with a combination of standard camera photography and computer-based image processing algorithms. The mechanical complexity of high-speed cameras is substituted with software-based particle detection and counting methods

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If high-speed cameras are used, then spatter detection accuracy is improved, but cost increases

Engineering Contradiction:

Improvespatter detection accuracyVSAvoidequipment cost

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent employs inexpensive standard cameras instead of expensive high-speed cameras. The system uses affordable imaging equipment combined with software processing to achieve spatter detection, replacing costly hardware with a more economical combination of cheaper hardware and computational analysis

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Measurement precision

If conventional spatter counting methods are used, then measurement accuracy is improved, but portability deteriorates

Engineering Contradiction:

Improvespatter counting accuracyVSAvoiddevice portability

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The patent uses a standard camera that can be easily transported and deployed in various welding environments. The same portable camera device performs multiple functions including image capture, spatter detection, and counting, making the system both portable and accurate without requiring specialized fixed equipment

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12103120B2Spatter counting method, computer program, and spatter counting device

Publication Date: 2024.10.01 NIPPON SANSO CORP

AI summary

One object of the present invention is to provide a technique capable of counting the spatters by a simple method while suppressing costs, and the present invention provides a spatter counting method performed by a portable terminal device provided with an image capturing device comprising: an image capturing step of capturing a moving image of an area including spatters generated during welding: and a counting step of counting a number of the spatters captured in each still image constituting the moving image captured in the capturing step.