3D Stator Winding Weld Inspection for Bare Zone Detection
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Solution Overview
Problem
Current quality control methods for welding joints in inductive windings of stators rely on human operators, which are time-consuming, costly, and prone to inaccuracies and human errors.
Innovation Solution
A method using a computer to acquire a 3D reconstruction of the welding joint, extract a 2D grayscale blob area, calculate the center of mass, and analyze profiles to identify and calculate bare zones and the bare area, thereby classifying the welding joint's quality level.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If human operators perform quality control of welding joints, then subjective judgment can be applied, but the process becomes time-consuming and costly
Solution Approach 1:
The patent replaces the mechanical human visual inspection system with an automated optical measurement system that captures images of welding joints and uses image processing algorithms to objectively measure and evaluate welding quality, thereby eliminating time-consuming manual inspection while maintaining or improving measurement precision
Solution Approach 2:
The patent creates a digital copy (image) of the welding joint and analyzes this copy through computational methods rather than requiring direct human observation, enabling rapid automated quality assessment without the time constraints of manual inspection
2Adaptability or versatility
If human operators perform quality control of welding joints, then flexibility in judgment is maintained, but human errors increase
Solution Approach 1:
The patent substitutes the human judgment system with an automated image processing system that applies consistent measurement criteria, eliminating human errors while maintaining the ability to adapt to different welding joint types through programmable evaluation parameters
Solution Approach 2:
The patent implements an automated feedback mechanism where measurement results are immediately processed and classified, providing consistent and reliable quality control decisions without the variability and error-proneness of human judgment
3Device complexity
If traditional image processing methods are used, then simplicity is maintained, but measurement precision deteriorates due to lack of 3D information
Solution Approach 1:
The patent transitions from 2D image processing to 3D measurement by capturing depth information and reconstructing the welding joint geometry in three dimensions, enabling precise measurement of welding characteristics that cannot be accurately determined from 2D images alone
Data Source
AI summary
A method for quality control of a welding joint between a pair of ends of conducting elements of an inductive winding of a stator, the method being performed by a computer and comprising the steps that consist in:acquiring a 3D reconstruction of the welding joint;extracting a white 2D grayscale blob area from the 3D reconstruction of the welding join;calculating a center of mass of the 2D grayscale blob area;extracting a plurality of profiles from the 3D reconstruction of the welding joint);searching for and identifying bare zones of the welding joint by analyzing one by one the profiles of the 3D reconstruction; andcalculating a bare area of the welding joint by summing the bare zones identified by the analysis of the profiles of the 3D reconstruction.