Welding Monitoring Optics for Full-Circumference Focus
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Solution Overview
Problem
Existing quality monitoring systems for welded products with different sizes face challenges in achieving uniform focus across multiple surfaces using a single camera, requiring complex rearrangement of optical systems and increased resources.
Innovation Solution
A welding monitoring system that includes a transport arm, subject holding portions, and imaging means with optical path length adjustment using mirrors and refractive materials to maintain focus across the entire circumference of the subject, allowing for automatic focusing and efficient imaging of components with varying sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple cameras are used to image multiple surfaces of the subject, then the imaging coverage is improved, but the system complexity and installation space increase
Solution Approach 1:
The patent uses a single camera to image multiple surfaces of the subject by utilizing optical reflections from mirrors positioned at different angles. This transforms a spatial problem (needing multiple cameras for multiple surfaces) into an optical path problem, where light from different surfaces is redirected to a single imaging sensor, achieving multi-surface coverage without increasing the number of cameras.
Solution Approach 2:
The patent introduces mirrors as intermediary elements between the subject and the single camera. These mirrors act as mediators that redirect light paths from different surfaces of the subject to the camera sensor, enabling the single camera to capture images of multiple surfaces that would otherwise require multiple cameras positioned at different locations.
2Measurement precision
If the camera position is adjusted to focus on subjects of different sizes, then the imaging accuracy is improved, but the time and resources required for rearrangement increase
Solution Approach 1:
The patent employs an adjustable optical system with movable mirrors and adjustable optical path lengths that can dynamically adapt to different subject sizes. This dynamic configuration allows the system to maintain proper focus and imaging accuracy for various subject dimensions without requiring physical relocation of the camera, thereby eliminating rearrangement time while preserving imaging precision.
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
Enables high-accuracy, multidimensional monitoring of welding portions with a simple configuration, ensuring all surfaces are in focus without the need for extensive rearrangement, thus reducing time and resource requirements.
Implementation Method 1
an optical path length adjustment portion (28) in front of the light receiving surface (6) on the path through which the optical paths (27A to 27D) pass. The optical path length adjustment portion (28) uses a transparent material (for example, glass or crystal) of which a refractive index is equal to or greater than 1
Data Source
AI summary
There are provided a welding monitoring system which can multidimensionally monitor a welding portion with high accuracy and a monitoring method thereof, by using a relatively simple configuration.There is provided a welding monitoring system which monitors a subject, including: a mechanical portion; and an imaging portion, in which the mechanical portion includes a transport arm which transports the subject, a subject holding portion which holds the subject, and an energizing device which causes welding with respect to the subject to be performed, and in which the imaging portion includes imaging means for obtaining imaging data of the subject, a data recording portion which records the imaging data, an analyzing portion which extracts predetermined characteristics from the imaging data, a comparison determination portion which compares the extracted characteristics and normal characteristics to each other to determine the presence or absence of abnormality, and a determination result output portion which outputs a determination result by the comparison determination portion.