Welding Torch Detector Multi-Angle Imaging
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Solution Overview
Problem
Existing welding torch detectors struggle to prevent interference between a deformed welding torch and welding tools or peripheral devices, as they only measure the tip position of the welding wire and torch, failing to account for the torch's inclination and deformation.
Innovation Solution
A welding torch detector system that includes an imaging unit to capture images of the torch and wire from multiple directions, an image recognition unit to recognize shapes, a setting unit to set a target point, a position detection unit to determine the wire's position in 3D space, and an inclination detection unit to assess the torch's inclination in 3D space, allowing for precise control and prevention of interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If only the tip position of the welding wire and torch is measured, then the measurement system remains simple, but it becomes impossible to prevent interference when the welding torch is deformed
Solution Approach 1:
The patent transitions from measuring only the tip position (2D/3D point) to capturing images from multiple directions (adding angular/directional dimensions). By taking images from at least two different directions and analyzing the welding torch's appearance in each, the system detects inclination and deformation in additional spatial dimensions, enabling reliable interference prevention while maintaining reasonable system complexity through image processing rather than adding numerous sensors.
2Measurement precision
If multiple imaging units are added to detect torch inclination and deformation, then detection precision improves, but device complexity increases
Solution Approach 1:
The imaging unit(s) serve multiple functions: capturing welding wire position, detecting torch inclination angle, and identifying torch deformation. Instead of adding separate sensors for each measurement function, the patent uses image capture and processing to achieve all three detection goals simultaneously, improving measurement precision while avoiding proportional increases in device complexity.
Solution Approach 2:
The patent introduces image processing analysis as an intermediary between the imaging unit and the detection goals. Rather than directly measuring inclination and deformation with specialized sensors, the system uses images as an intermediary medium, processing the visual data to extract positional, angular, and deformation information, thereby achieving high precision without linearly increasing hardware complexity.
3Measurement precision
If images are captured from multiple directions, then torch deformation detection accuracy improves, but processing time and complexity increase
Solution Approach 1:
The patent captures images from multiple directions (excessive action) to ensure complete detection of torch deformation, but processes only the necessary features from these images (partial action). By selecting and analyzing only the critical image features needed for deformation detection rather than processing all image data in full detail, the system achieves high detection accuracy while minimizing processing time and computational overhead.
Data Source
AI summary
A welding torch detector including an imaging unit capturing images of a welding torch and welding wire from a plurality of directions to acquire image signals, an image recognition unit recognizing welding wire images and welding torch images based on the image signals acquired, a setting unit setting a target point corresponding to a target position of the welding wire on the welding wire images recognized, a position detection unit detecting a position of the target point in a three-dimensional space based on the welding wire images recognized, and an inclination detection unit detecting an inclination of the welding torch in the three-dimensional space based on the welding torch images recognized.