Weld Reflection Circularity Inspection for Dust-Robust Quality Checks
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Solution Overview
Problem
Existing welded portion inspection methods are inefficient and prone to erroneous determinations due to the use of entire image analysis, which can be affected by dust, leading to incorrect assessment of welding quality.
Innovation Solution
A device and method utilizing a circular light projection, image capture, circumscribed rectangle, and inscribed circle analysis to determine the circularity of the reflection region, with thresholds for determining normal or abnormal welding states, thereby improving efficiency and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the entire image of the welded portion is used to determine the presence or absence of a defect, then the inspection coverage is comprehensive, but the inspection time increases and determination accuracy decreases due to dust interference
Solution Approach 1:
The patent segments the welded portion image into multiple regions of interest based on geometric characteristics. Instead of analyzing the entire image, the system divides it into specific areas that are most relevant for defect detection, thereby reducing processing time while maintaining determination accuracy. This segmentation allows the inspection system to focus computational resources on critical areas only.
Solution Approach 2:
The patent applies different analysis methods to different regions of the welded portion image. By identifying areas with specific characteristics (such as regions prone to dust accumulation versus regions critical for welding quality), the system applies localized quality assessment criteria. This enables accurate defect determination without being unduly influenced by dust in non-critical areas.
2Reliability
If the entire image of the welded portion is used for inspection, then all areas are covered, but dust on the surface causes erroneous abnormal determinations
Solution Approach 1:
The patent extracts and removes the harmful effect of dust from the inspection process. By identifying and excluding regions where dust is likely to accumulate (such as peripheral areas or surfaces with specific geometric features), the system prevents dust from causing erroneous abnormal determinations. This extraction of harmful factors maintains determination reliability while ignoring non-critical contamination.
Solution Approach 2:
The patent converts the presence of dust into a beneficial filtering mechanism. By analyzing the spatial distribution and characteristics of dark regions in the image, the system identifies dust particles and automatically excludes them from the defect assessment. This approach transforms the harmful dust interference into an opportunity to refine the inspection criteria and improve overall determination reliability.
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
Enhances work efficiency and determination accuracy by accurately distinguishing between normal and abnormal welding states, even in the presence of dust, by using circularity calculations and thresholds.
Implementation Method 1
an imaging unit configured to capture an image of the welded portion, the image including a reflection region of the light in the welded portion
Data Source
AI summary
In a welded portion inspection device and a welded portion inspection method, an image of a welded portion including a reflection region of light is captured in a state where the light having a circular cross-sectional outer shape is projected on the welded portion. For the image, a circumscribed rectangle of the reflection region and an inscribed circle of the circumscribed rectangle are created. When the circularity of the inscribed circle is equal to or greater than a secondary determination threshold, the welding state of the welded portion is determined to be good.