Conductor Weld Seam Pixel Imaging for Non-Destructive Quality Evaluation
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Solution Overview
Problem
Existing methods for quality control of weld seams between conductor elements in electric motors are costly, complex, and prone to errors, with non-destructive methods requiring additional equipment and being slow or limited to examining one seam at a time.
Innovation Solution
A method and device that capture an image of the weld seam, divide it into subsets based on intensity levels, and assess the welding quality by comparing pixel subsets with target values, allowing for non-destructive, fast, and precise evaluation of multiple seams simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If cross-section through the weld seam is used for quality control, then measurement precision is improved, but device complexity and loss of time increase due to destructive testing requirements
Solution Approach 1:
The patent uses optical coherence tomography to create a non-contact 3D copy of the weld seam structure, allowing virtual analysis without physical sectioning. This copying approach enables repeated measurements and detailed inspection while avoiding the destructive nature of traditional cross-section methods.
Solution Approach 2:
The patent replaces mechanical cutting and physical sectioning of the weld seam with an optical measurement system. By using light-based optical coherence tomography, the system achieves detailed structural analysis without mechanical intervention, thereby avoiding destructive testing and reducing equipment complexity.
2Measurement precision
If optical coherence tomography or laser sensor is used for weld bead measurement, then measurement precision is improved, but loss of time increases due to slow measurement speed
Solution Approach 1:
The patent implements continuous scanning of the weld seam using optical coherence tomography, where the measurement system moves continuously through the weld region to capture complete structural information. This continuous action enables fast acquisition of comprehensive data without the stop-start nature of point-by-point measurements.
Solution Approach 2:
The patent uses periodic scanning patterns where the optical coherence tomography system systematically repeats measurements across different depths and positions of the weld seam. This periodic sampling strategy efficiently collects comprehensive data while maintaining fast measurement speeds through optimized scan sequences.
3Ease of operation
If lateral image of welded hairpins is used for quality control, then ease of operation is improved, but device complexity and loss of time increase due to additional equipment and single-seam limitation
Solution Approach 1:
The patent makes the optical coherence tomography system multi-functional by using it for both the primary welding process monitoring and subsequent quality control measurement. This universal application eliminates the need for separate dedicated inspection equipment, reducing device complexity while maintaining ease of operation.
Solution Approach 2:
The patent merges the welding process and quality control functions into a single integrated system. By combining the laser welding apparatus with optical coherence tomography capability, the system performs both welding and non-contact measurement simultaneously, eliminating the need for separate inspection equipment and enabling multi-seam evaluation.
4Productivity
If process light measurement is used for quality control, then productivity is improved by avoiding additional equipment, but measurement precision deteriorates due to difficulty in establishing exact correlation
Solution Approach 1:
The patent introduces optical coherence tomography as an intermediary measurement system that directly visualizes the weld seam structure. This intermediary approach provides a direct link between the welding process and the actual weld quality, eliminating the indirect and imprecise correlation problems of process light measurement while maintaining high productivity.
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 cost-effective, rapid, and reliable quality control of weld seams, reducing errors and equipment costs while allowing simultaneous evaluation of multiple seams, thereby improving production efficiency.
Implementation Method 1
The image is captured with different intensity levels for each pixel of the image. The intensity levels are an indicator of the amount of light that was reflected locally by the recorded position when the image was taken.
Data Source
AI summary
A method for evaluating a welding quality of a weld seam with which the end sections of conductor elements are welded to one another by irradiating their end faces. The method includes capturing an image of the end faces and dividing the image into a first subset of pixels whose intensity levels are greater than a specified intensity level threshold value and into a second subset of pixels whose intensity levels are less than or equal to the intensity level threshold value. The method includes assessing the welding quality of the weld seam based on a comparison of a number and/or position of the pixels of the first subset and/or of the second subset with a pixel target value of a number and/or a pixel target range of a position of pixels of the first subset and/or of the second subset that correspond to a weld seam of desired quality.