Visual Weld Part Recognition for Automatic Parameter Setting
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Solution Overview
Problem
Manual adjustment of welding power sources for intricate welds is time-consuming and prone to variations, reducing efficiency and accuracy in welding processes, particularly in applications like aerospace part welding.
Innovation Solution
A welding system that includes a visual acquisition system to capture digital images of the weld part, a part recognition system to identify features, and a method to compare these features to stored data to automatically set appropriate welding parameters for the welding power supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment of welding power sources is used for intricate welds, then the welding process can be performed with traditional equipment, but the setup time increases and parameter accuracy decreases
Solution Approach 1:
The welding system automatically identifies workpiece features and sets welding parameters without operator intervention. The visual acquisition system captures images, the part recognition system identifies features, and the control system automatically configures welding parameters, enabling the system to serve itself rather than requiring manual setup by operators.
Solution Approach 2:
The patent replaces manual mechanical adjustment of welding parameters with an automated optical and computational system. Instead of operators manually adjusting dials and switches, the system uses visual acquisition, image processing, and automated control to set parameters, substituting mechanical manual operations with automated electronic control.
2Productivity
If automated welding systems are implemented, then productivity and consistency improve, but the complexity of the system increases
Solution Approach 1:
The welding system integrates multiple functions into a single automated platform. The visual acquisition system serves both inspection and parameter setting purposes, the part recognition system identifies various workpiece features, and the control system manages multiple welding parameters and processes, reducing the need for separate specialized equipment.
Solution Approach 2:
The patent introduces a part recognition system as an intermediary between the visual acquisition system and the welding control system. This intermediary layer processes images, identifies workpiece features, and translates them into welding parameters, simplifying the overall system architecture by breaking down the automation into manageable functional blocks.
3Adaptability or versatility
If manual parameter setting is used for different welding applications, then the system remains simple to operate, but the adaptability to different workpieces decreases
Solution Approach 1:
The system automatically adjusts welding parameters based on identified workpiece features. By changing parameters dynamically according to the specific workpiece being welded, the system achieves high adaptability across different applications without requiring operators to manually reconfigure settings for each workpiece type.
Solution Approach 2:
The welding system performs preliminary identification and parameter setting automatically before the welding operation begins. The visual acquisition and part recognition systems prepare the welding parameters in advance based on workpiece features, eliminating the need for operators to perform manual setup tasks during production.
Data Source
AI summary
An example welding system includes: a visual acquisition system comprising an imaging device and configured to acquire a visual representation of a weld part and to convert the visual representation into data representative of weld part features; and a part recognition component comprising processing circuitry configured to: receive the digital data; identify one or more features of the weld part in response to receipt of the digital signal; compare the digital signal to stored data of a plurality of weld parts stored in a weld part database to match one or more identified features to a known weld part of the plurality of weld parts stored in the weld part database; identify weld settings stored in a weld parameter database associated with the matching known weld part of the plurality of weld parts stored in the weld part database; and send the weld settings to a welding power supply.