Weld Seam Localization Using Controlled Light for Gap Measurement
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Solution Overview
Problem
Existing robotic welding systems face challenges in accurately localizing weldable seams and measuring seam gaps due to irregularities in seam width and susceptibility to surface finishes in 3D point clouds.
Innovation Solution
A robotic welding system that uses an artificial light source to emit controlled light onto weldable objects, allowing cameras to capture images that enable precise localization of weldable seams and measurement of seam gaps, even in the presence of varying surface finishes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If 3D point clouds are used to measure seam gap width, then measurement capability is provided, but measurement precision deteriorates due to seams appearing as empty spaces or voids and susceptibility to surface finish variations
Solution Approach 1:
The patent introduces an artificial light source as an intermediary between the camera and the weldable objects. This light source illuminates the objects to create visible contrast at seam locations, allowing the camera to detect seam positions and gap widths accurately. The light acts as a mediator that transforms the invisible or indistinct seam regions into detectable features, resolving the problem of seams appearing as empty spaces in 3D point clouds.
Solution Approach 2:
The patent utilizes optical contrast changes caused by artificial illumination to differentiate seam regions from object surfaces. By controlling the light source to create specific illumination patterns and contrast variations at seam locations, the system can distinguish between actual gaps and surface finish variations. This approach transforms the measurement problem from detecting geometric voids to detecting optical contrast patterns.
2Difficulty of detecting and measuring
If 3D scanning is used to generate point clouds for seam detection, then seam localization capability is provided, but detection difficulty increases due to surface finish susceptibility creating false gaps
Solution Approach 1:
The artificial light source serves as an intermediary that enhances the visibility of actual seams while suppressing the visual impact of surface finish variations. By strategically positioning and controlling the light, the system creates illumination patterns that highlight true gap locations without being affected by reflective or absorptive surface properties, thereby reducing false positive detections.
Solution Approach 2:
The patent changes the illumination parameters (light intensity, angle, and distribution) to optimize seam detection. By adjusting these optical parameters, the system can create contrast conditions that make actual seams visible while rendering surface finish variations invisible or less significant, thereby simplifying the detection process and improving measurement precision.
3Measurement precision
If conventional vision sensors are used without controlled illumination, then system complexity is reduced, but measurement precision deteriorates due to inability to handle varying surface finishes and seam irregularities
Solution Approach 1:
The patent integrates the artificial light source with the existing camera system to create a multi-functional vision system. The light source not only illuminates the workspace but specifically enhances seam detection capability. This universal approach allows a single integrated system to handle both general workspace illumination and specific seam measurement tasks, improving precision without proportionally increasing complexity.
Solution Approach 2:
The artificial light source acts as an intermediary component that bridges the gap between conventional vision sensors and the requirements for accurate seam measurement. Rather than replacing the entire vision system, the light source is added as a mediating element that enhances the capabilities of existing sensors, thereby improving measurement precision with minimal increase in overall system complexity.
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
The system achieves accurate seam localization and gap measurement, improving the quality of welds by reducing errors associated with irregular seam widths and surface finishes.
Implementation Method 1
controlling a light source to emit light at a first object and a second object
Implementation Method 2
When the light is incident on the weldable objects, the robotic welding system is configured to capture images of the weldable objects
Data Source
AI summary
This disclosure provides systems, methods, and apparatuses, including computer programs encoded on computer storage media, which provide for welding techniques for manufacturing robots, such as seam localization, gap measurement, or both. For example, the welding techniques may include, during illumination of one or more objects by a light source, controlling a camera to capture images of the one or more objects along at least a portion of a length of a seam formed by the one or more objects. The techniques further include differentiating, in the images, the seam from the one or more objects. In a first aspect, the techniques also include triangulating the differentiated seam to identify a position of the seam relative to a reference point. In a second aspect, the techniques also include determining, based on the differentiated seam, gap information along a portion of the seam. Other aspects and features are also claimed and described.