Welding Vision Sensor with Multi-Filter Image Merging
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Solution Overview
Problem
Existing vision sensor systems fail to accurately capture and process images of welding processes, where the camera is overwhelmed by the brightness of the welding arc, making it difficult to identify the welding bead and surrounding environment.
Innovation Solution
The vision sensor system employs a camera unit with a shading cartridge structure that controls light entering a camera, and a shading cartridge structure that includes a shading cartridge structure that controls light entering a camera, and transmits the captured image to an external device, allowing a welding bead, a welding arc, and a surrounding environment to be identified together with the laser line through the image.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a blackening filter is arranged in front of a camera to identify the laser line, then the laser line can be identified in the image, but the welding arc brightness overwhelms the camera making 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 blackening filter densities. Each filter density captures different aspects of the welding scene, and these segmented images are then synthesized to create a complete high-definition welding image that includes both the laser line and the welding bead with surrounding environment visible.
Solution Approach 2:
The patent changes the parameter of blackening filter density to capture multiple images under different light transmission conditions. By using filters with varying densities (e.g., different optical densities), the system captures both the bright laser line and the darker welding bead and surrounding environment, then synthesizes these images to achieve full visibility.
2Measurement precision
If multiple image frames are captured and merged to generate high-definition welding images, then the welding bead and surrounding environment can be clearly identified, but the system complexity increases
Solution Approach 1:
The patent merges multiple image frames captured with different blackening filter densities into a single high-definition welding image. The synthesis process combines the advantageous information from each image frame, resulting in a complete image that shows both the laser line and the welding bead with surrounding environment clearly.
Solution Approach 2:
The patent introduces an image synthesis module as an intermediary that processes multiple captured images and generates the final high-definition welding image. This intermediary component automatically handles the complex processing of merging multiple frames, reducing the operational complexity for the user while achieving high-definition results.
3Area of stationary object
If the camera captures the entire welding area including the bright welding arc, then the surrounding environment can be seen, but the welding arc brightness causes overexposure and loss of detail
Solution Approach 1:
The patent applies dynamic adjustment by using multiple blackening filter densities to adapt to different light intensity conditions in the welding area. The system dynamically selects and combines images captured with different filter densities, allowing the effective exposure to be adjusted for different regions of the welding scene, thereby preventing overexposure while maintaining full area coverage.
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 effectively generates a high-definition welding image capable of clearly showing the welding bead, arc, and surrounding environment, while preventing ghost phenomena and adjusting light density to shield unnecessary light, enabling real-time defect detection and process control.
Implementation Method 1
a shading cartridge structure which controls light entering a camera
Implementation Method 2
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 3
a laser irradiation unit configured to irradiate a laser along an imaginary welding path set on a target object
Implementation Method 4
a camera unit configured to obtain a plurality of image frames for the target object based on the laser
Data Source
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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.