Weld Nugget Pattern Matching for Small Workpiece Identification
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Solution Overview
Problem
Existing methods for managing workpieces with welds, such as those in disk device suspensions, face challenges in identifying and tracking individual pieces due to the difficulty in displaying IDs on small components and the complexity of production management systems using hash values.
Innovation Solution
A management device comprising a camera, image processing unit, and control unit that captures and processes nugget patterns of welds to link pattern data with product IDs, allowing for identification and information retrieval without the need for explicit ID display on the workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an ID is displayed on a very small work piece, then the work piece can be identified, but the display may affect the work piece and it is difficult to display on small components
Solution Approach 1:
The patent uses the weld nugget pattern as a natural copy or fingerprint of the work piece. Instead of adding an external ID tag, the unique characteristics of the weld pattern itself serve as the identification marker. The camera captures and processes this natural pattern to generate a hash value that identifies the work piece without requiring any additional display elements on the work piece itself.
2Reliability
If a production management system using hash values is implemented, then work pieces can be strictly managed, but the system becomes large and lacks simplicity
Solution Approach 1:
The patent extracts only the essential identification function from a complex management system. Instead of implementing a full hash-based production management system, it extracts the core capability of using weld pattern recognition for identification. The system takes out just the necessary components: camera for capture, image processing unit for pattern recognition, and database for storing and retrieving work piece information based on the generated hash values.
3Manufacturing precision
If laser spot welding is used to join small metal plates, then high quality welds are achieved, but the work pieces require special management to maintain quality through multiple processes
Solution Approach 1:
The weld nugget pattern, which is inherently created during the laser spot welding process to achieve high quality joints, also serves as the identification marker. The same welding process that creates the functional weld also creates the unique pattern used for tracking and management. This self-service approach eliminates the need for separate identification marking processes and simplifies the overall management system.
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
Enables efficient management and identification of workpieces by capturing and processing nugget patterns to obtain product IDs, reducing the complexity of production management and avoiding potential interference from ID displays.
Implementation Method 1
The camera captures the weld of the work piece
Implementation Method 2
The image processing unit obtains pattern data by subjecting a nugget pattern of the weld captured to image processing
Data Source
AI summary
A work piece includes a weld. A management device includes a camera, a control unit, and a database. Information on the work piece and a product ID are linked to each other and stored in the database. The weld of the work piece is captured and a nugget pattern thereof is subjected to image processing to obtain pattern data. The pattern data is linked to the product ID and stored in the database. A weld of a work piece with an unknown product ID is captured and a nugget pattern is subjected to image processing to obtain check data. This check data is checked against the existing pattern data, and when the matching data and the existing pattern data match, the product ID linked to the existing pattern data is acquired.