Weld Inspection Overlay for Fast Positional Deviation Checks
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Solution Overview
Problem
Current inspection methods for welded portions require manual measurement of positional deviations using 2D design drawings, which is inefficient and skill-dependent, and results are typically recorded on paper.
Innovation Solution
An inspection system that includes a display unit, an acquisition unit, a display control unit, and a distance calculation unit, which virtually superimposes a reference position image on a captured image of a welded object, allowing for easy measurement of distance between the welded portion and the reference position, and stores the results in a paperless manner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual measurement with 2D design drawings is used, then inspection can be performed, but inspection efficiency is low and requires skilled inspectors
Solution Approach 1:
The patent creates a 3D copied model of the welded object from design drawings and superimposes it with the actual captured image. This allows automated distance calculation between the welded portion and reference position without manual measurement, eliminating the need for skilled inspectors to interpret 2D drawings and significantly improving inspection efficiency
Solution Approach 2:
The patent replaces the manual mechanical measurement process with an automated image processing and distance calculation system. The system automatically calculates distances using coordinate information from superimposed images, eliminating manual measurement operations and reducing dependency on inspector skills
2Productivity
If paper-based recording is used, then inspection results can be stored, but storage efficiency is low and costs are high
Solution Approach 1:
The patent replaces the physical paper-based recording system with a digital storage system. Inspection results including calculated distances are stored in database tables with structured data formats, eliminating paper consumption and improving storage efficiency through automated digital record-keeping
Data Source
AI summary
An inspection system for a welded portion in welding includes a display unit, an acquisition unit that acquires a reference position of a welded portion stored in the storage device, a display control unit that displays, on the display unit, a reference position image that is an image showing a reference position virtually superimposed on an image of an object to be welded in a real space captured by the imaging device and includes a welded portion, and a distance calculation unit that calculates a distance in the real space between the welded portion in the real space displayed on the display unit and the reference position of the welded portion.