Welding Camera Stress Prediction from Real-Time Sharpness Changes
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Solution Overview
Problem
Current computer simulation methods for monitoring stress changes during the welding process of automotive cameras require significant computing resources and are limited by the complexity and accuracy of simulation models, making them inefficient and inaccurate.
Innovation Solution
A method and system that utilize an image resolution algorithm to determine sharpness change rates from acquired images, which are then input into a sharpness stress mapping model to predict stress changes in real-time, without relying on extensive computational resources or complex simulation models.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If computer simulation methods are used to monitor stress changes during welding, then stress prediction can be achieved, but large amounts of computing resources are required and accuracy is limited by simulation model complexity
Solution Approach 1:
The patent replaces complex mechanical/computational simulation systems with an optical measurement system. By using a camera to capture image sequences during welding and analyzing sharpness changes through optical principles, the system achieves stress prediction without requiring complex simulation models or extensive computing resources.
Solution Approach 2:
The patent introduces image sharpness as an intermediary parameter that mediates between the physical stress state and the measurement system. Instead of directly measuring stress through complex simulations, the system uses sharpness changes of captured images as an intermediate indicator that correlates with stress variations, simplifying the measurement process.
2Measurement precision
If computer simulation methods are used to monitor stress changes during welding, then stress prediction can be achieved, but large amounts of computing resources are required
Solution Approach 1:
The patent replaces computationally intensive simulation methods with lightweight optical measurement and image processing. By capturing images with a camera and analyzing sharpness changes, the system achieves stress prediction with minimal computing resource consumption, eliminating the need for heavy simulation computations.
Solution Approach 2:
The patent uses inexpensive image capture and processing instead of expensive computational simulations. The method relies on standard camera equipment and simple image analysis algorithms that require minimal computing power, making the system cost-effective and energy-efficient compared to resource-intensive simulation approaches.
3Productivity
If multiple welding points are welded simultaneously to improve production efficiency, then productivity increases, but material stress changes occur during the welding process
Solution Approach 1:
The patent implements real-time feedback monitoring of stress changes during simultaneous welding operations. By continuously capturing image sequences and analyzing sharpness changes, the system provides immediate feedback on stress variations, enabling operators to adjust welding parameters or sequences to minimize adverse stress effects while maintaining high productivity.
Solution Approach 2:
The patent dynamically monitors stress changes during the welding process by analyzing temporal variations in image sharpness. This dynamic approach allows the system to track stress evolution in real-time during simultaneous welding of multiple points, enabling adaptive control to optimize both productivity and stress management.
Data Source
AI summary
A method, system, and readable storage medium for monitoring welding camera, the method comprises: determining that a device to be welded is in a welding process, and acquiring a set of images of the device to be welded; obtaining a sharpness change rate according to the set of images by utilizing an image resolution algorithm; and inputting the sharpness change rate into a sharpness stress mapping model to obtain a stress change of the device to be welded.