3D Scanning Welding Condition Diagnosis for Perpendicular Joints
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Solution Overview
Problem
Current welding bead quality inspection methods, such as manual leg gauges and 3D vision inspection systems, face challenges in accurately measuring and distinguishing welding beads between base materials intersecting perpendicularly, leading to material bursting and errors in welding quality assessment.
Innovation Solution
A welding condition evaluation apparatus and system that utilizes a communication unit, base material recognition unit, bead extraction unit, and profile analysis unit to receive and analyze three-dimensional images of welding beads, extracting and analyzing cross-sections to determine welding quality and detect defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a manual leg gauge is used to measure welding beads, then the device is small, portable, easy to use, and inexpensive, but a large number of processes are required to ensure data accuracy due to large measurement time, manual data recording errors, and inability to measure acute or obtuse angle base materials
Solution Approach 1:
The patent replaces the manual mechanical leg gauge system with an automated 3D vision inspection system using cameras and image processing algorithms. This substitution eliminates manual measurement errors, reduces measurement time, and enables automated data analysis while maintaining portability and ease of use through software-based operation.
Solution Approach 2:
The patent creates a digital 3D model (copy) of the welding bead and base material geometry through photogrammetry. This digital replica allows for repeated, error-free measurements and analysis without physical contact, eliminating the need for manual data recording and enabling precise measurement of complex geometries including acute and obtuse angles.
2Productivity
If a three-dimensional vision inspection system is used to inspect welding beads, then digital images can be acquired quickly and shape information can be obtained rapidly, but the system cannot clearly distinguish the welding bead and base materials when they intersect perpendicularly
Solution Approach 1:
The patent transitions from 2D image analysis to 3D point cloud processing and cross-sectional analysis. By examining the welding bead in three-dimensional space and analyzing cross-sections at different positions, the system can clearly distinguish the bead from perpendicularly intersecting base materials, resolving the ambiguity that plagues 2D vision systems.
Solution Approach 2:
The patent segments the welding bead into multiple cross-sectional slices at different positions along its length. This segmentation allows for detailed analysis of the bead profile at each cross-section, enabling clear distinction from base materials even in perpendicular intersections, while maintaining high inspection speed through automated processing.
3Device complexity
If visual quality inspection by operator is used, then the process is simple and inexpensive, but material bursting occurs frequently in post-process because pinholes cannot be detected
Solution Approach 1:
The patent replaces human visual inspection with automated 3D vision inspection and image processing algorithms. This substitution enables detection of pinholes and internal defects that are invisible to the human eye, significantly improving defect detection reliability while maintaining simple and inexpensive operation through software-based analysis.
Solution Approach 2:
The patent introduces 3D imaging and cross-sectional analysis as an intermediary between the welding process and quality assessment. This intermediary reveals hidden defects such as pinholes by creating detailed digital models and analyzing cross-sectional profiles, enabling detection of defects that would otherwise remain undetected.
Data Source
AI summary
Disclosed are an apparatus and system for evaluating a welding condition on the basis of three-dimensional data. An aspect of the present embodiment provides an apparatus for evaluating a welding condition, the apparatus including a communication unit configured to receive a three-dimensional image for an evaluation target from the outside, a base material recognition unit configured to recognize a base material from the three-dimensional image for the evaluation target by using a point cloud, a bead extraction unit configured to extract a welding bead welded between the base materials, a bead cross-section acquisition unit configured to acquire cross-sections at preset intervals for the extracted welding bead, and a profile analysis unit configured to analyze a profile of the welding bead for the cross-section acquired by the bead cross-section acquisition unit.