Welded Conductor Joint Inspection Using Intensity and Depth Data
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for assessing the quality of welded connections between conductor ends in electric machines are time-consuming and inefficient, particularly due to the use of X-ray analysis, which requires significant equipment and time.
Innovation Solution
A method utilizing intensity and depth information from image points of the welded connection, combined with machine learning, to determine a quality criterion, such as connection area or pore volume, through a device comprising an image-acquisition and depth-information acquisition system, and a processor unit for precise and efficient quality assessment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If X-ray analysis is used to determine connection area, then measurement precision is improved, but loss of time increases and device complexity increases
Solution Approach 1:
The patent replaces the mechanical X-ray analysis system with an optical measurement system using a camera to capture images of the welded connection. The camera acquires intensity information that is then processed to determine the connection area, eliminating the need for complex X-ray equipment and reducing inspection time while maintaining measurement capability.
Solution Approach 2:
The patent creates an optical copy (image) of the welded connection area using a camera instead of using physical X-ray imaging. This optical copy contains sufficient information to determine the connection area through image processing, avoiding the time-consuming and complex X-ray analysis process while preserving the essential measurement data.
2Measurement precision
If X-ray analysis is used to determine connection area, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent substitutes the complex X-ray analysis device with a simple camera-based optical system. The camera captures images of the welded connection, and standard image processing techniques are used to determine the connection area, dramatically reducing device complexity while maintaining measurement functionality.
Solution Approach 2:
The patent uses optical copying through camera imaging to create a visual representation of the welded connection. This optical copy can be processed using software algorithms to extract connection area information, eliminating the need for complex X-ray hardware while preserving the essential measurement capability.
3Productivity
If intensity information and depth information are acquired for quality determination, then productivity is improved, but device complexity increases
Solution Approach 1:
The patent combines intensity information acquisition and depth information acquisition into a single integrated measurement system. The camera captures both the visual appearance (intensity) and depth characteristics of the welded connection simultaneously, enabling rapid quality assessment without requiring multiple separate measurement devices or sequential operations.
Solution Approach 2:
The patent employs a multi-functional measurement system where the camera and processing unit can extract multiple quality parameters (connection area, pore volume, other defects) from the same set of intensity and depth information. This universal approach allows rapid determination of various quality criteria without requiring separate specialized equipment for each measurement type.
Data Source
AI summary
A method for determining a quality criterion of a welded connection between two conductor ends. The method includes acquiring intensity information of a plurality of image points and depth information of the plurality of image points of an acquisition area covering the two conductor ends, and determining a quality criterion as a function of the intensity information acquired and the depth information acquired.