Welding Line Detection Using Marker-Based 3D Coordinate Mapping
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Solution Overview
Problem
The existing welding robot operation teaching systems require laborious manual drawing of welding lines on the object to be welded, which can damage the surface and are inefficient, and do not accurately detect the welding lines without manual input.
Innovation Solution
A welding line detection system that uses a photographing terminal to capture images, sets a user coordinate system based on a marker, detects the marker's position, plots point group data, and identifies welding lines as intersections between surfaces, allowing for efficient detection and production of a work program for the robot.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual drawing of welding lines is performed by a worker, then welding line information can be obtained for robot teaching, but the work requires laborious operation and may damage the surface of the object
Solution Approach 1:
The patent replaces the manual mechanical drawing operation with an automated optical scanning system. A photographing terminal captures images of the object surface, and a welding line detection unit automatically identifies welding lines through image processing, eliminating the need for workers to manually draw lines with pens and thereby improving both efficiency and surface quality.
Solution Approach 2:
The system enables the object itself to provide the welding line information through its surface characteristics. The photographing terminal captures the object's surface features, and the detection algorithm automatically extracts welding lines from these features without requiring external manual intervention, allowing the object to 'self-reveal' its welding requirements.
2Loss of information
If manual drawing of welding lines is performed, then welding portions can be indicated, but the lines drawn with the pen may remain on the surface of the object to be welded
Solution Approach 1:
The patent replaces the mechanical pen-drawing process with a non-contact optical detection system. The photographing terminal uses light to capture surface information, and the welding line detection unit processes these optical signals to identify welding lines, completely avoiding mechanical contact that could damage or leave marks on the object surface.
Solution Approach 2:
The system creates a digital copy of the object's surface information through photographing. Instead of physically marking the surface with pen lines, the system captures an optical copy of the surface features and processes this digital representation to identify welding lines, thereby preserving the original surface without any physical alterations.
3Productivity
If welding lines are detected automatically using image processing, then work efficiency can be improved, but the system complexity increases
Solution Approach 1:
The photographing terminal serves multiple functions: it captures images of the object surface, identifies welding lines through integrated processing, and provides the data for robot teaching. By combining these functions into a single device, the system reduces overall complexity compared to having separate manual operations for each task while maintaining high efficiency.
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
This system enables efficient operation teaching for welding robots by accurately detecting welding lines without manual drawing, improving welding quality and efficiency by allowing the robot to follow detected lines, even when the worker cannot access all areas.
Implementation Method 1
a photographing terminal that photographs an image of an object to be welded
Implementation Method 2
point group data acquired by a distance measurement sensor that measures a distance to the object to be welded
Data Source
AI summary
The welding line detection system includes a photographing unit that photographs an image of an object to be welded, a coordinate system setting unit that sets a user coordinate system based on a marker included in the photographed image, a point-group-data plotting unit that detects a specific position of the marker on the basis of the image, sets the detected specific position on point group data acquired by a distance measurement sensor that measures a distance to the object to be welded, and plots, in the user coordinate system, the point group data to which coordinates in the user coordinate system, using the set specific position as an origin, are given, and a welding line detection unit that detects, on the basis of the point group data plotted in the user coordinate system, a welding line of the object to be welded.