Twin Laser Camera Assembly for Compact Weld Joint and Bead Sensing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current robotic welding systems require separate laser cameras for joint tracking and weld bead inspection, which are cumbersome, difficult to position symmetrically, and not suitable for harsh environments due to space and calibration challenges.
Innovation Solution
A compact, robust twin laser camera assembly with first and second laser range finders mounted symmetrically on a robot processing tool, capable of joint and bead measurement and inspection in both forward and backward directions, integrated into a single housing with an onboard controller for real-time data processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If two separate laser cameras are mounted on a robot arm for joint tracking and weld bead inspection, then joint measurement and bead inspection can be performed simultaneously, but the mounting becomes problematic due to space constraints and the arrangement requires 310 mm or more space around the welding torch
Solution Approach 1:
The patent combines two separate laser cameras into a single integrated camera unit that performs both joint tracking and weld bead inspection functions. This merging eliminates the need for two separate camera mounts and reduces the overall space requirement around the welding torch from 310 mm or more to a compact integrated structure.
Solution Approach 2:
The integrated laser camera unit is designed to perform multiple functions simultaneously - joint measurement, bead inspection, and tracking - within a single device. This multi-functionality allows the system to replace multiple separate cameras while maintaining all necessary measurement and inspection capabilities in a space-efficient configuration.
2Measurement precision
If two separate laser cameras are used for joint tracking and weld bead inspection, then both functions can be performed, but each camera requires absolute spatial calibration and steady behavior over long operating periods which is very difficult to achieve
Solution Approach 1:
By integrating two laser cameras into a single unitary assembly, the patent reduces calibration complexity from two separate absolute spatial calibrations to one unified calibration process. The integrated design ensures both cameras maintain steady behavior relative to each other and the welding torch, eliminating the difficulty of maintaining calibration for two independent cameras over long operating periods.
3Adaptability or versatility
If two separate laser cameras are mounted on a robot arm, then joint tracking and bead inspection can be performed, but the arrangement is difficult to position symmetrically with respect to the welding torch for welding in both forward and backward directions
Solution Approach 1:
The integrated laser camera unit is designed with an asymmetric configuration that can be mounted on the robot arm in different orientations. This asymmetric design allows the same unit to serve both forward and backward welding directions by simply changing the mounting orientation, eliminating the need for separate symmetric arrangements for each welding direction.
4Measurement precision
If two separate laser cameras are used, then joint and bead measurement can be performed, but each camera requires separate electronic control boards, electric cables and air supply tubes which complicates the system
Solution Approach 1:
The patent merges the electronic control boards, electric cables, and air supply tubes of two separate cameras into a single integrated unit. This consolidation reduces the number of separate components and connections required, simplifying the overall system while maintaining the dual functionality of joint tracking and bead inspection.
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 solution simplifies mounting, improves accessibility, reduces cycle time, and enhances data processing efficiency while providing accurate joint and bead geometry data in a robot reference frame, suitable for harsh environments with reduced space requirements.
Implementation Method 1
laser projectors for projecting laser beams crosswise to the direction of displacement of the robot processing tool
Implementation Method 2
corresponding imagers with fields of view respectively over target areas at the look-ahead and look-back distances where the laser beams are projected
Data Source
AI summary
A twin laser camera unitary assembly for a robot processing tool is disclosed. The assembly has a housing having a front wall defining an upright U-shaped channel into which a tubular portion of the tool is laterally insertable. A mounting support attaches the housing relative to the tool in operative position. Twin laser range finders are respectively mounted in the housing on opposite sides of the U-shaped channel in a symmetrical in-line arrangement with respect to the tool. A controller mounted in the housing is configured to receive robot control signals, operate laser projectors and process image signals produced by imagers of the laser range finders so that joint and bead position and geometry signals are produced in a robot reference frame. The assembly is designed and protected for use in industrial processes such as robotic laser and arc welding and sealant dispensing.