Welding Object Tracking with Multi-Exposure Camera Control
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Solution Overview
Problem
In welding processes, especially with laser welding, the high dynamic range of welding light and environment makes it difficult for workers to identify and track critical objects like the welding torch or tip due to automatic exposure adjustments, leading to potential errors in delicate and fine part welding.
Innovation Solution
A device and method that use a camera system with adjustable camera control parameters such as exposure value, color gain, gamma value, and black level to capture and track specific objects in a welding image, providing an augmented reality output to enhance visibility and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the camera adjusts exposure value based on average image brightness, then the overall image brightness is balanced, but the welding torch or specific objects become unidentifiable due to high dynamic range lighting
Solution Approach 1:
The patent divides the image processing into multiple exposure value settings (first exposure value for overall brightness, second exposure value for specific object brightness). This segmentation allows different parts of the image to be captured with appropriate exposure levels, enabling both overall scene visibility and specific object identification to be optimized simultaneously.
Solution Approach 2:
The patent changes the camera exposure value parameter from a single fixed value to multiple variable values. By adjusting the exposure value based on the brightness characteristics of specific objects (welding torch, welding line) rather than relying solely on average image brightness, the system can accurately identify objects in high dynamic range welding environments while maintaining overall image quality.
2Ease of operation
If the worker monitors welding progress using a camera with automatic exposure, then the welding process can be observed, but welding quality deteriorates due to inability to identify critical objects
Solution Approach 1:
The patent implements a feedback mechanism where the system continuously monitors image brightness values, identifies specific objects (welding torch, welding line), and automatically adjusts the exposure value based on the detected object characteristics. This feedback loop ensures that the camera maintains optimal settings for identifying critical welding objects, thereby preserving welding quality while enabling effective monitoring.
Solution Approach 2:
The camera system performs self-adjustment of exposure values by automatically detecting the brightness characteristics of welding objects and modifying its own settings accordingly. This self-service capability eliminates the need for manual intervention to optimize exposure settings, allowing the worker to monitor welding progress effectively while maintaining high identification accuracy for critical objects.
3Manufacturing precision
If laser welding is performed with visual monitoring, then delicate and fine parts can be welded, but errors occur due to inability to properly grasp welding situation under welding light
Solution Approach 1:
The patent makes the camera exposure value dynamic rather than static. The exposure value is continuously adjusted based on real-time detection of welding object brightness characteristics. This dynamic adaptation allows the system to maintain optimal visibility of delicate welding objects throughout the welding process, ensuring both precision and reliability even in the challenging high dynamic range environment created by welding light.
Data Source
AI summary
According to an embodiment, an object tracking device in a welding process tracks and outputs a predetermined object in a welding image. The object tracking device comprises a camera device capturing the welding image including a base material and a welding torch for welding the base material, a controller receiving a plurality of camera control parameter-varied images from the camera device, identifying the predetermined object in the received images, and generating an object tracking image, the plurality of camera control parameter-varied images having varied camera control parameters of the camera device, and an output device outputting the welding image captured by the camera device, the plurality of images received by the controller, or the object tracking image generated by the controller.