Welding Vision Sensor Imaging With HDR and Arc Light Filtering
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Solution Overview
Problem
Existing vision sensors struggle to capture high-definition images during welding processes due to the excessive brightness of the welding arc, making it difficult to identify the welding bead and surrounding environment apart from the laser line.
Innovation Solution
A vision sensor system with a shading cartridge structure that controls light entering the camera, including a blackening filter and neutral density filter, to capture and transmit images that clearly show the welding bead, arc, and surrounding environment, using high dynamic range technology to generate high-definition images.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a blackening filter is arranged in front of the camera to identify the laser line, then the laser line can be identified in the image, but the welding arc brightness makes it difficult to identify the welding bead and surrounding environment
Solution Approach 1:
The patent divides the image processing into multiple segments by capturing multiple images with different filter configurations (blackening filter for laser line, neutral density filter for overall brightness control) and then merging them to obtain comprehensive welding area information including laser line, welding bead, and surrounding environment
Solution Approach 2:
The patent introduces a neutral density filter as an intermediary element between the welding arc and the camera sensor. This filter attenuates the excessive brightness of the welding arc, allowing the camera to capture both the laser line and surrounding environment details simultaneously without being overwhelmed by the arc's intensity
2Loss of information
If the welding arc brightness is reduced to identify the welding bead and environment, then visibility improves, but the laser line identification becomes difficult
Solution Approach 1:
The patent segments the imaging task into multiple captures: one image captured with a blackening filter to identify the laser line, and another image captured with a neutral density filter to show the welding bead and surrounding environment, which are then merged into a comprehensive image
Solution Approach 2:
The patent dynamically adjusts the filter configuration based on the imaging requirements. The system switches between different filter states (blackening filter for laser line emphasis, neutral density filter for overall brightness control) to optimize both laser line identification and surrounding environment visibility in different capture phases
3Manufacturing precision
If multiple filters are used to control light, then welding image quality improves, but device complexity increases
Solution Approach 1:
The patent designs the filter system with multi-functionality where the same camera and image processing system handle multiple imaging tasks (laser line identification, welding bead detection, surrounding environment monitoring) by switching between different filter configurations, avoiding the need for separate dedicated systems for each function
Solution Approach 2:
The patent implements a dynamic filter system that can switch between different filter configurations (blackening filter, neutral density filter, or no filter) based on the current imaging requirements. This dynamic adaptability allows a single system to handle multiple imaging scenarios without requiring multiple fixed systems
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
The system enables real-time identification of welding defects by distinguishing the welding bead, arc, and environment, allowing for immediate adjustments to the welding process to minimize defects.
Implementation Method 1
a blackening filter and a neutral density filter are provided inside a camera unit to control a blackening density or a neutral density according to the presence or absence of welding light or the intensity of welding light
Implementation Method 2
unnecessary light reflected from a camera is prevented from entering the camera again by adjusting a slope of a shading cartridge structure of a camera unit, which limits a ghost phenomenon that may occur due to unnecessary light
Data Source
AI summary
A vision sensor system is provided. The vision sensor system may include a laser irradiation unit configured to irradiate a laser along an imaginary welding path set on a target object, and a camera unit configured to obtain a plurality of image frames for the target object based on the laser and generate one or more merged images, based on two or more image frames selected from among the plurality of image frames in accordance with a set criterion.