Weld Bead Line-Scan Inspection for Automated Conformity Checks
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Solution Overview
Problem
Current welding processes lack an efficient and automated method to monitor weld bead quality, specifically the height and length of the weld bead face, which affects the volume and integrity of the weld, leading to potential fragility and non-compliance with quality standards.
Innovation Solution
A system comprising a robot with an imaging device and a computing device that captures a line scan of the weld bead, analyzes the profile to determine the volume, rising edge, and falling edge, and compares these parameters to predetermined standards to assess weld quality, allowing or rejecting parts based on conformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If automated monitoring of weld bead quality is implemented, then weld quality assurance is improved, but device complexity increases
Solution Approach 1:
The patent replaces manual visual inspection and mechanical measurement methods with an automated imaging system that uses cameras and image processing algorithms to capture and analyze weld bead geometry. The system substitutes mechanical profilometers or calipers with optical field-of-view analysis to measure weld height, length, and volume, thereby improving reliability while managing complexity through automation.
Solution Approach 2:
The patent creates a digital copy of the weld bead by capturing its image within the camera's field of view and generating a line scan profile. This optical copy allows for precise measurement of weld characteristics without physical contact, enabling automated quality assessment while avoiding the complexity of mechanical measurement systems.
2Manufacturing precision
If precise measurement of weld bead characteristics is performed, then manufacturing precision is improved, but measurement difficulty increases
Solution Approach 1:
The patent replaces difficult mechanical measurement of weld bead height and volume with optical imaging and image processing. The system captures the weld bead within the field of view, converts the image to a line scan profile, and automatically calculates characteristics such as weld height, length, and volume through software algorithms, thereby achieving precise measurement while eliminating manual measurement complexity.
Solution Approach 2:
The patent transforms the three-dimensional weld bead measurement problem into a two-dimensional image analysis problem by capturing the weld within the camera's field of view and converting it to a line scan profile. This dimensional reduction simplifies the measurement process while maintaining precision through automated image processing and profile analysis.
3Productivity
If automated weld inspection is implemented, then productivity is improved, but device complexity increases
Solution Approach 1:
The patent implements a self-service automated inspection system where the imaging device automatically captures weld bead images, processes the images through line scan profile generation, and performs quality assessment without human intervention. The system autonomously measures weld characteristics, compares them against specifications, and determines pass/fail status, thereby improving productivity while containing complexity through integrated automation.
Solution Approach 2:
The patent incorporates feedback by automatically comparing measured weld bead characteristics against predetermined specifications and providing immediate quality determination. The system uses the captured image and derived profile to generate real-time feedback on weld quality, enabling rapid decision-making and maintaining productivity while managing complexity through automated decision logic.
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
This system enables automated and precise monitoring of weld bead quality, ensuring that welds meet predetermined parameters, thereby enhancing the reliability and consistency of welds by identifying and rejecting substandard welds, ensuring proper assembly.
Implementation Method 1
a robot with an imaging device that captures a line scan of the weld bead
Data Source
AI summary
Embodiments described herein are for determining a weld quality by an imaging device configured to generate one or more signals indicative of a weld bead positioned on at least one part. Machine-readable instruction set causes a computing device to perform at least the following when executed by the processor: capture an initial scan to determine a plurality of offset information based on predetermined part features, activate the imaging device to capture a scan of the weld bead, establish a line scan profile of the weld bead, determine that the scan of the weld bead matches a predetermined weld model, and analyze the weld bead profile to determine a volume of the weld bead, a rising edge of the weld bead, and a falling edge of the weld bead and comparing the weld bead profile to a plurality of predetermined parameters for the weld bead to determine a satisfactory weld quality.