Welding Monitoring Optics for Full-Circumference Focus Accuracy
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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 an imaging system with mirrors and optical path length adjustment components 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 combines multiple imaging functions into a single camera by using a beam splitter and multiple mirrors. The beam splitter divides the light from different surfaces of the subject, and mirrors redirect these light paths to the single camera sensor, enabling simultaneous imaging of multiple surfaces without requiring multiple cameras.
Solution Approach 2:
The beam splitter acts as an intermediary optical element that separates light from different surfaces while directing it to a single camera. This intermediary component enables one camera to capture images of multiple surfaces that would otherwise require separate cameras.
2Measurement precision
If the optical system is rearranged to accommodate 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 adjustable mirror angles and movable optical components that can be dynamically reconfigured for different subject sizes. The mirror angles can be adjusted to change the imaging field of view, allowing the system to adapt to various subject dimensions without complete rearrangement of the optical system.
Solution Approach 2:
The system changes optical parameters such as mirror angles and focal lengths to accommodate different subject sizes. By adjusting these parameters, the single camera can maintain imaging accuracy across various subject dimensions without requiring physical rearrangement of the entire optical system.
3Measurement precision
If the camera position is moved to focus on different parts of the subject, then the focus accuracy for specific areas is improved, but the ability to focus on the entire imaging target region simultaneously is worsened
Solution Approach 1:
The optical system segments the light paths from different surfaces of the subject using beam splitters and mirrors. Each surface's light is separated and directed to specific regions of the camera sensor, allowing the system to maintain focus across the entire imaging target region by capturing segmented views simultaneously rather than requiring the camera to be positioned for each surface individually.
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.