Vision-Guided Welding Path Calibration for Variable Focal Length
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In vision-guided welding systems, changes in the working distance due to varying workpiece contours or clamping postures cause focal length adjustments in cameras, leading to pixel size offsets and inaccurate calculation of movement distances for welding tools.
Innovation Solution
The method involves adjusting the camera's focal length to focus on the workpiece surface, determining the current focal length, calculating the corrected pixel length using a focal length-corrected pixel length correspondence relationship, and then determining the distance between the start and end points of the welding tool's movement based on the corrected pixel length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a fixed pixel length is used for calculation, then the calculation process is simple, but it cannot accurately reflect the actual pixel size when focal length changes, leading to welding position errors
Solution Approach 1:
The patent transforms the static fixed pixel length approach into a dynamic system where the pixel length adapts to changing focal lengths. The system maintains a correspondence relationship between focal length and pixel length, automatically selecting or calculating the appropriate pixel length based on the current focal length setting. This dynamic adaptation ensures welding position accuracy without requiring complex recalculation procedures, as the relationship between focal length and pixel length is pre-established.
Data Source
AI summary
A method for welding a workpiece with a vision guided welding platform. The welding platform comprises a welding tool, and a camera for guiding the movement of the welding tool from a start point to an end point. The method includes the steps of adjusting a focal length of the camera such that a focal plane of the camera is located on a surface of the workpiece and obtaining a surface image of the workpiece. The method further includes the steps of determining a current focal length of the camera, determining a corrected pixel length of a pixel in the surface image and determining the number of pixels between the start point and the end point of each movement of the welding tool. Using the corrected pixel length, a distance between the start and end points is determined and the welding tool is guided to move therebetween.