Spot Welding Tip Inspection Housing for Noise-Free Image Analysis
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Solution Overview
Problem
Conventional methods for inspecting welding tips of spot welding guns are inefficient and time-consuming, particularly in analyzing contamination and alignment, due to reliance on visual inspection and the need for multiple inspection apparatuses, which also suffer from noise issues in image analysis.
Innovation Solution
An apparatus with an external housing, internal housing, lighting unit, camera unit, and control unit that allows for simultaneous inspection of both welding tips, using light diffusing units and sensors to acquire clear images of the welding tips, enabling efficient analysis of contamination and alignment through image processing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple inspection apparatuses are used for different inspection processes, then inspection coverage is improved, but inspection time and operational complexity increase
Solution Approach 1:
The patent combines multiple inspection functions (alignment inspection, end diameter inspection, zero point inspection, and contamination inspection) into a single integrated inspection apparatus. The housing contains multiple sensors positioned to perform all these inspections simultaneously on welding tips inserted into the apparatus, eliminating the need to move the welding tip between different inspection devices and thereby reducing total inspection time while maintaining comprehensive inspection coverage.
Solution Approach 2:
The inspection apparatus is designed as a universal device that can perform multiple types of inspections on welding tips through a single setup. By incorporating various sensors (alignment sensors, end diameter sensors, zero point sensors, and contamination sensors) within one apparatus, it serves multiple inspection purposes that previously required separate dedicated devices, thus improving operational efficiency.
2Extent of automation
If vision inspection is performed with external light exposure, then inspection automation is improved, but image quality deteriorates due to noise
Solution Approach 1:
The patent creates a controlled light environment within the housing by blocking external light from reaching the welding tip during inspection. The housing structure includes light-blocking features that prevent external light interference, creating an optically controlled environment similar to an inert atmosphere. This allows the vision inspection system to capture high-quality images without noise from external light sources while maintaining full automation.
Solution Approach 2:
The patent introduces lighting units as intermediary devices that provide controlled illumination from within the housing. These lighting units act as mediators between the vision system and the welding tip, providing sufficient light for image capture without allowing external light to interfere. This controlled illumination enables high-quality automated vision inspection by mediating the light interaction in a controlled manner.
3Ease of operation
If operator visual inspection is performed, then inspection flexibility is maintained, but inspection reliability and efficiency decrease
Solution Approach 1:
The patent replaces the manual visual inspection system with an automated sensor-based inspection system. Multiple sensors (alignment sensors, end diameter sensors, zero point sensors, and contamination sensors) automatically measure welding tip parameters without requiring operator visual assessment. This substitution of mechanical/manual inspection with automated sensing systems significantly improves inspection reliability and efficiency while maintaining operational ease through automated workflows.
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
Significantly reduces the time required for image analysis and improves inspection efficiency by providing clear, noise-free images, allowing for batch processing of welding tips and enhancing the accuracy and reliability of contamination and alignment inspections.
Implementation Method 1
a light diffusing unit arranged being separated from an inner surface of the internal housing toward a center of the internal housing by a predetermined distance and configured to diffuse the light provided to the inspection space
Data Source
AI summary
The present invention discloses methods and apparatus for increasing inspection efficiency and reducing time for analyzing an image when inspecting contamination and alignment of the welding tip of the spot welding gun. An apparatus for inspecting a welding tip according to some embodiments of the present invention is configured to inspect the contamination and the alignment of the welding tip based on an end-surface image and a profile image of the welding tip. In particular, when recording the welding tip through an internal housing arranged in an internal space of an external housing, the noise generated from an external light source can be blocked, and hence the contamination and the alignment of the welding tip can be inspected by using a clearer image, thus improving the accuracy of the inspection.