CN107107231A

CN107107231A - Weld video and control system

Info

Publication number: CN107107231A
Application number: CN201580068143.9A
Authority: CN
Inventors: 杰弗里·T·佩诺耶; 泰勒·M·克朗; 迈克·J·戴维斯; 兰斯·盖蒙; 迈克尔·S·马丁
Original assignee: Lincoln Global Inc
Current assignee: Lincoln Global Inc
Priority date: 2014-12-19
Filing date: 2015-12-18
Publication date: 2017-08-29
Also published as: WO2016100950A2; JP2018503515A; DE112015005683T5; WO2016100950A3

Abstract

One kind welding video generates multiple composographs (for example with control system (100), 255,398,478,578,1032,1260), these composographs can be imaged in single composograph or in the video flowing of composograph for the bright feature and dark feature in the welding region (109) of welding process, be controlled for welding system (102) manually and automatically change.From in the periodicity power waveform powered to the welding system (for example, 136,202,302,402,502,1002,1202) exposure period occurred during moment generates multiple original images (for example, 204 ', 304 ', 404 ', 504 ', 1031,1224 ').These exposure periods (for example, 204,304,404,1004,1224) can be by detecting the threshold level of the electrical characteristic in the periodicity power waveform or being triggered with time delay.Some of welding feature occurs during the moment of the periodicity power waveform, and by creating exposure period during these moments, such feature can be isolated in real time and be checked in video is shown.These composographs be by during the different exposure time section duration, during the different phase of the periodicity power waveform, different camera sensitivity and aperture set or multiple original images for obtaining of combination of these parameters in select independent unsaturation and non-dark pixel is generated.

Description

Weld video and control system

Background

Generally, welding refers to material (for example, metal) part being attached in a permanent fashion by causing material fusion Manufacturing process together.This fusion requirement of adjacent metal material pieces is enough the energy of fusing metal.Arc-welding is typical weldering Connect method, wherein, energy necessary to fusing metal be by least one metalwork in these metalworks and metal electrode it Between high voltage electric arc provide, the metal electrode is slowly melted away at the point that electric arc occurs from the electrode, from And electrode metal molten bath is produced, the molten bath is fused together with these adjacent metal parts.When the metal in molten bath and adjacent Metalwork cool down when, fusion it is metal-cured, so as to create the two welded connections of metalwork permanent link together.Through Nian Lai, welding system and technology continue improving.For example, gas tungsten arc welding (TIG) uses non-expendable tungsten electrode To produce welding.Electrode wire is sent into weld zone with adj sp moreover, gas metal arc welding (MIG) is used Wire feed rifle, and some such welding procedures with electrode wire the starting the arc far-end formation fusing electrode wire liquid Drop causes electrode wire to be moved back and forth toward and away from molten metal bath.Some species of limited automatic welding is developed System, these systems reduce essential for what is welded manually in many industrial welding environment.MIG and TIG weld system In power supply improvement also obtained it is easy use and produce high quality welds welding machine.

The electric arc of heat also creates very strong, high-energy necessary to generation makes metal molten in electric arc welding Visible ray, ultraviolet radioactive and the infra-red radiation of radiation-emitting, such as incandescent.Such radiation it is so strong and cause people from See to ongoing electric arc welding process, the ultraviolet radioactive otherwise with very high flash burn risk, wherein high intensity Cause the retina of the inflammation of cornea and the human eye that may burn.Therefore, welder must be worn with dark-coloured, filtering ultraviolet The goggles of face cover plate welds the helmet to prevent such eye injury.Such face cover plate is so dark, and cause people from See normal visible ray through them, therefore welder must remove the helmet when not welding and can just see but must assure that It is in place so as to protect eyes to start welding foregoing description face cover plate to excite welding arc.More in recent years, for welder the helmet Develop the face cover plate dimmed immediately when being exposed to strong ultraviolet light.

The content of the invention

A kind of welding video and control system for arc welding system, wherein the arc welding system is carried out self-brazing The periodicity power waveform for connecing power supply powers to produce bead, the welding video and control on workpiece in welding region System includes：(i) camera, the camera has the light focused in the feature on the welding region or in the welding region Sensor array, the camera starts control signal to cause the photosensor array to from the weld zone in response to exposure It is that domain or the luminous energy that sends or reflect from the feature in the welding region expose to produce the welding region or described A series of original images of the feature in welding region；And (ii) video system controller, the video system control Device starts control signal at the predetermined trigger point on periodicity power waveform to the camera generation exposure.In a reality Apply in example, when the electrical characteristic that the video system controller is sensed in the periodicity power waveform starts threshold value with exposure Match and start control signal to the camera generation exposure as response.In another embodiment, the weldering Connect predetermined trigger point of the power supply on the periodicity power waveform to the camera provide it is described exposure start control signal with Just the exposure is started.In another embodiment, the source of welding current is provided and the week to the video system controller The corresponding trigger signal of predetermined trigger point on phase property power waveform, and in response to the trigger signal, the video system Controller of uniting starts control signal to the camera generation exposure.In another embodiment, the periodicity electric power wave Predetermined trigger point in shape is manually or automatically variable.

A kind of being used to creating welding region by periodicity power waveform in the welding process the powered or weld zone A series of method of original images of feature in domain, electrical characteristic periodically changes in the periodicity power waveform, Methods described includes：(i) camera is focused in the feature on the welding region or in the welding region；And (ii) the magazine photosensor array pair is caused in the predefined phase triggering camera of the periodicity power waveform The luminous energy for sending or reflecting from the feature in the welding region or the welding region exposes a series of time for exposure Section, so as to the original image of the feature in welding region that create the welding region or described.

It is a kind of for the special characteristic checked in the welding process powered by periodicity power waveform in welding region Method, electrical characteristic periodically changes during the periodicity power waveform, and methods described includes：(i) camera is gathered Jiao is on the welding region, wherein the camera starts control signal to start so that the magazine light in response to exposure Sensor array exposes a series of exposure periods to the luminous energy for sending or reflecting from the feature in the welding region； (ii) during these periods the periodicity power waveform first stage generation it is described exposure start control signal with Just so that the photosensor array exposes to the luminous energy for sending or reflecting from the welding region, so as to produce from the system A series of composographs of row exposure period；(iii) by the series of composite images crossfire of the feature to display device For being subject to the first stage of the feature in the periodicity power waveform as described to the feature in the welding region Period existing ground video is shown；And (iv) changes these exposure periods and is allowed to difference in the periodicity power waveform Stage occurs, in these exposure periods appear in the stage that the special characteristic is present, so that the specific spy Levy in the series of composite images being illustrated in during the video is shown.

Therefore embodiments of the invention can include a series of a kind of composographs for being used to produce from camera to generate weldering The method of the video of termination process, methods described includes：To the first operator scheme of video camera using multiple operating parameters so as to Generate multigroup single image of the welding process；Led to using the waveform created by the arc welder for performing the welding process Cross in the following manner multigroup single image is synchronous with the welding process：In response to the operating parameter on the waveform First group of position at multiple first trigger pulses are provided, these first trigger pulses be used to opening the shutter of the camera from And the single figure that every single image in any given group in multigroup single image is organized at other There is the correspondence image that the substantially the same position on the waveform is triggered as in；In response to the operating parameter described Multiple second trigger pulses are provided at second group of position on waveform, these second trigger pulses be used to close on the camera The shutter so that every single image in any given group in multigroup single image is in other groups The single image in have therewith have substantially the same exposure period correspondence image；By will be described multigroup single The single image in image is combined to create the combination image, so as to create described from multigroup single image Series of combination image；The video of the welding process is generated from the series of combination image；Analyze the welding process The video is to provide the analysis to the welding process；The welding process is changed in response to the analysis.

Embodiments of the invention may further include a kind of system for being used to generate the video of welding process, the system Including：Wire feed welding machine, the wire feed welding machine is welded multiple metal weldments to produce weld seam；The source of welding current, the weldering Connect power supply and produce the power supply wave shape for being applied to the welding machine；Camera with shutter, the camera is aligned for response Ground generates multigroup single image of the welding process；Controller, the controller senses the power supply wave shape and described Multiple first trigger pulses are produced at first group of position on waveform, these first trigger pulses be used to open on the camera The shutter so that every single image in any given group in multigroup single image is all described There is the correspondence image that the substantially the same position on the waveform is triggered in multigroup single image；And in the waveform On second group of position at produce multiple second trigger pulses, these second trigger pulses be used to close the institute on the camera Shutter is stated so that every single image in any given group in multigroup single image is all described multigroup There is exposure period that the substantially the same position on the waveform starts, being substantially identical in single image Correspondence image；The controller carries out logical operation to combine the single image in every group of single image, is suitable for showing to produce The combination image for showing and analyzing.

Brief description of the drawings

Fig. 1 is the schematic block diagram for the exemplary embodiment for welding video and control system；

Figure 1A is the enlarged perspective of the welding region of welding system；

Fig. 2 is the diagrammatic view of the exemplary progress exposure technique using single threshold value trigger point；

Fig. 3 is the diagrammatic view with the exemplary progress exposure technique from the trigger point of threshold delay；

Fig. 4 is the diagrammatic view of the exemplary constant exposure technique using variable trigger delay amount；

Fig. 5 is the diagrammatic view of the exemplary variable exposure technique using variable trigger delay amount；

Fig. 6 A are the flow charts of the operation for the exemplary weld video and control system for showing Fig. 1；

Fig. 6 B are the flow charts for the operation for showing video system controller；

Fig. 7 illustrates the example system for starting magazine exposure；

Fig. 8 can be used for the example that the pixel stream from each exposure as seen in figs. 2-5 is alignd in time The diagrammatic illustration of sexual system；

Fig. 9 is the block diagram shows of the exemplary embodiment of image combiner；

Fig. 9 A are the diagrammatic illustrations for selecting the example system of unsaturation or non-dark pixel；

Fig. 9 B are the diagrammatic illustrations that exemplary bright range pixel selects system；

Fig. 9 C are the diagrammatic illustrations that exemplary dark range pixel selects system；

Figure 10 is for creating the diagrammatic view that the exemplary original image of composograph merges；

Figure 11 is the diagrammatic view of exemplary picture point time alignment；

Figure 12 A are that the exemplary DC shapes power waveform of displaying and the exemplary weld corresponding to the stage of the power waveform show The figure of elephant；

Figure 12 B, 12C and 12D are the figures for showing the exemplary imaging system based on the stage；And

Figure 13 is the diagrammatic illustration that exemplary manual welds video system.

Embodiment

Welding video and control system 100, the welding video and control system are illustrated with schematic block diagram in Fig. 1 Image, such as composograph 140 of welding process can be created, merged and shown, and such image can be used The welding process is fed back and controlled.The exemplary weld video is shown as tool in Fig. 1 with control system 100 There are exemplary arc welding system 102, such as gas metal arc welding (MIG) system.However, welding video and control System 100 can be used for other welding systems, such as Manual metal pole electrical arc weldering (also commonly referred to as rod weldering), flux-cored wire electricity Arc-welding, submerged-arc welding, gas shield tungsten electrode (TIG) welding, welding wire move back and forth, cold metal transfer (CMT) and other.Showing In the MIG arc welding systems 102 of example property, wire electrode 106 through from welding wire source of supply 118 by wire feeder 120 and weldering In (invisible) the feeding welding region 109 in tip in machine nozzle 104, in the welding region by two metalworks, for example Metal works 110,112 weld together.The source of welding current 122 produces waveform 136, and the waveform is electrically connected to an electrode 106.Gold Metal work-pieces 110,112 are electrically grounded to the source of welding current 122, therefore the voltage that power supply 122 is provided is in silk electrode 106 and these metals Electric arc 107 is produced between workpiece 110,112.Electric arc 107 generates conduction between silk electrode 106 and metal works 110,112 Plasma 108.It is continuously applied voltage and maintains high current and flows through between the distal end of an electrode 106 and workpiece 110,112 Plasma 108, this generates the gold of some in the metal for the far-end for being enough to melt an electrode 106 and workpiece 110,112 The heat of category, electric current is assembled in silk electrode 106 and workpiece, and fusion zone 113 is thus created in workpiece 110,112.From silk The drop 121 (Figure 1A) of the distal end molten metal of electrode 106 forms metal bath 111, the metal bath and workpiece 110th, 112 fusion zone 113 is fused together, while gas device 116 guides inertia or half inert protective gas from gas Source of supply 114 flows through soldering machine nozzle 104 to protect welding position from pollution.As soldering machine nozzle 104 and silk electrode 106 are along arrow First 105 mode is moved, and the metal stayed in welding pool 111 and fusion zone 113 cools down and solidified to form solid metal Bead 103, the solid metal bead by the two workpiece 110,112 permanent links together.

Electric arc 107 and electric current in exemplary MIG welding systems 102 through plasma 108 is just as other arc weldings The electromagnetic radiation of high intensity is equally produced in welding system, for example, the visible ray of incandescent, ultraviolet radioactive and infra-red radiation.It is such Radiation is so strong and causes people from seeing the welding region 109 to ongoing electric arc welding process, otherwise with very high Damage human eye (such as flash burn) risk, the ultraviolet radioactive of wherein high intensity causes the inflammation of cornea and may burn Retina.Therefore, welder must wear welding goggles or the helmet with dark-coloured, filtering ultraviolet face cover plate (in Fig. 1 not Show) to prevent eye injury.Such face cover plate is so dark, and causes people from seeing normal visible ray through them. Therefore welder must remove the helmet when not welding and can just see but must assure that exciting welding arc to start to weld the foregoing description Face cover plate carrys out protect eyes in place, acceptable compared with low-intensity water so as to which most strong visible ray and ultraviolet radioactive are decayed into human eye It is flat.People can see that the remaining light of most bright part for still passing through the dark goggles or face cover plate and ongoing welding The feature of process, such as electric arc 107 and plasma 108, but other features of such intense radiation are not sent or reflect, For example the bead 103 of cooling, the outward flange of fusion zone 113 and in welding region 109 metal works 110,112 phase Adjacent part, is at all invisible through such dark goggles or face cover plate.Therefore, people is limited to see and assess in real time The all these features and process of welding region 109 to instruct welding process, be estimated or quality control ability.It is similar Ground, conventional camera does not have dark in most bright feature and welding region 109 in welding region 109 in order to catch simultaneously The image of feature, especially with welding process to show these features in real time and required dynamic range.It should allow The aperture that enough light enters the photosensor array or photographic film of camera to catch the dark feature in welding region is set Also the so many high-strength light from most bright feature will be allowed to enter so that such high-strength light cause the film or Photosensor array, the part that is exposed in the most light become saturation so that the figure of welding region 109 caught Those parts of picture are meaningless and useless, and decay enough light to avoid imaging sensor or film from causing to satisfy by most light The aperture of sum sets the image for the relatively dark-part that will be unable to that these imaging sensors or film can be made to capture welding region 109.

By contrast, shown in Fig. 1 and the exemplary weld video that is described in more detail below is created with control system 100 Build composograph, the visible-range that the composograph is readily seen that with the progress of welding process with people is shown in real time All features in welding region 109 and it can be processed and monitor and optimize welding product for automatic welder control Matter.For example, the composograph produced by exemplary weld video and control system 100 can be checked to monitor and assess welding Process and adjustment welding parameter, for example, the voltage and/or electric current of exemplary arc welding system 102, the and of welding tip 104 Sophisticated (invisible in Fig. 1) sends into weld zone relative to the position of workpiece 110,112 and speed, by consumption sex pilus electrode 106 Speed, the size of welding pool 111 in domain 109 and can improve the establishment of welding system 102 weld seam other specification. The user of these parameters, which can be adjusted, can check these composographs, or can use the ginseng for being capable of adjust automatically welding process Several machine videos handles these composographs with mode identification technology.The composograph created can be used for manual weldering In connecing.For example, explaining as shown in Figure 13 and in more detail below, the welding helmet used in manual welding is specifically filled Have a display, the display allow welder with is formationed of bead 103 check in real time welding region 109 include own Composograph including feature, these are characterized in such as soldering machine nozzle 104, silk electrode 106, electric arc 107, plasma 108, weldering Connect the adjacent part in molten bath 111, fusion zone 113 and workpiece 110,112.These abilities are by creating wider array of visible ray The HDR of spectrum or image, by with different exposures, in different phase and will continue not during power supply wave shape 136 The independent image electrically caught with the period merges (combination) come what is realized, as explained below.These Composograph can also be stage by stage, to isolate and show the specific spy of one or more of welding region 109 in real time Levy, such as one or more positions between silk electrode 106 and welding pool 111 are this to be formed by consumption sex pilus electrode 106 Fusing metal liquid 121, as will be described in more detail.

With continued reference to Fig. 1, the source of welding current 122 can be controlled according to the specific metal welded, the electricity used Pole, desired welding characteristic, ambient influnence etc. output have the waveform 136 of different electric parameters, and these electric parameters are Such as electric current, voltage, impedance, frequency, waveform shape etc..Welding electricity can be independently controlled for these and other parameter Source 122, or can be controlled by video system controller 124, as shown in the link 125 in Fig. 1.Video system controller 124 can include programmable calculator or a series of logic circuits such as FPGA or state machine apparatus, can receive from welding The signal (as shown in control link 125) of power supply 122, such as instruction power supply wave shape 136 or the trigger point in power supply wave shape 136 Signal, as will be explained in greater.Video system controller 124 can also be from power supply wave shape 136, for example from voltage or electricity Current sensor 123 is inputted, as shown in the link 148 in Fig. 1.It is suitable for the voltage sensor and current detector of this application It is generally known and commercially available.Video system controller 124 may also connect on robot system controller 142, institute State robot system controller and generate control signal, these robot system actuators to multiple robot system actuators 144 Soldering machine nozzle 104 and electrode 106 are moved and shifted relative to workpiece 110,112.Filled there is provided appropriate mechanical linkage Put 146 and these robot system actuators 144 are connected to soldering machine nozzle 104, electrode 106 and arc welding system 102 Miscellaneous part on, as understood by those skilled in the art, therefore on such linkage 146 and actuator 144 Further describe and be not required to for understanding the present invention.User interface 128 is connected on video system controller 124, with Desired ripple is provided for control signal to be inputted to video system controller 124 to configure the source of welding current 122 Shape 136 and caused to configure the robot system controller 142 to provide desired input to these robot systems Dynamic device 144.This connection can be hardwire connection or wireless connection.Robot system controller 142 can be single list A part for member or video system controller 124.

Digital camera 126 is oriented to adjacent with arc welding system 102, and wherein it can focus on welding region 109 One or more of in feature, such as on electric arc 107, and adjacent with silk electrode 106 and welding pool 111, or focus on On whole welding region 109, feature as some or all of which is located in the welding region.If if wishing also Optional second digital camera 127 can be used to carry out three-dimensional imaging, such as below with respect to being welded manually shown in Figure 13 Described by the camera 1306 of system 1300.Original image applied to the camera control of camera 126, illumination, camera 126 is produced The raw, technology for creating composograph by original image and other information and explanation are also applied for optional second Camera 127.Digital camera 126 is controlled to create the original image of the feature in welding region 109, and these are characterized in for example to weld Machine nozzle 104, welding machine silk electrode 106, electric arc 107, plasma 108, drop 121 (Figure 1A), welding pool 111, fusion zone 113rd, the adjacent part of bead 103 and workpiece 110,112.In one embodiment, digital camera 126 is by from video system The signal of system controller 124 controls (as shown in the camera control link 129 in Fig. 1) light in digital camera 126 to be passed Sensor array exposes to the light for sending or reflecting from this category feature in welding region 109.In another embodiment, digital phase Machine controls (as shown in the optional camera control link 129 ' in Fig. 1) to cause digital phase by the signal from the source of welding current 122 Photosensor array in machine 126 exposes to the light for sending or reflecting from this category feature in welding region 109.Following article is more detailed Carefully explain, the different original images of welding and peripheral region are generated using different exposures, by this in controller 124 A little images merge (combination) together to create combination image, such as composograph 140, at user interface 128 or can appoint The composograph is checked in display device 138 at what other positions.These original images are shown under different exposures Feature in the welding region 109.By the way that the image with different exposures is combined, it is possible to be trapped among with high dynamic range All or selected features for being shown and checking in the welding region 109 simultaneously in composograph, and the one of welding region 109 A little features may be too bright and other secretly may cause photosensor array from single at one from single exposure very much Captured in image.For example, due to the different luminous intensities for sending or reflecting from these different characteristics in welding region 109, one Secondary exposure may can make the photosensor array (not shown) in camera 126 fairly efficiently capture the original of electric arc 107 Image, and one other exposure may can be such that the photosensor array in camera 126 more effectively captures in silk electrode 106 Melt the original image for the fusing metal drop 121 that far-end is produced.The light sensing of camera 126 may can be made by exposing again Device array captures the original image of welding pool 111 and fusion zone 113, and one other exposure may can make camera 126 Image capture sensor to other peripheral characteristics such as adjacent part of workpiece 110,112 and bead 103 of solidification original Beginning image.By the way that these different original images are merged into composograph, it is possible to composograph, such as Fig. 1 in gained All or selected key characters in welding region 109 are shown in composograph 140.Lamp 134 on camera 126 (lamp 135 on optional camera 127) can help to illuminate background or peripheral characteristic, such as weldment 110,112 when wishing With the bead 103 of solidification, and can reduce in order to such background characteristics is captured in original image and it is required needed for Time for exposure.

Fig. 2 is illustrated for the photosensor array (not shown) of camera 126 to be exposed to welding region 109 (Fig. 1) Exemplary exposure technology 200.In this exemplary exposure technology 200, corresponding on power supply wave shape start trigger point 228, 240th, the photosensor array of 252,264,232,244,256,268,236,248,260,272 triggering cameras 126 continues in succession The ground of exposure period 204,210,216,222,206,212,218,208,214,220,226 to from welding region 109 or weldering A series of exposures of luminous energy that the special characteristic in region 109 sends or reflected are connect, to produce a series of corresponding original graphs As 204 ', 210 ', 216 ', 222 ', 206 ', 212 ', 218 ', 208 ', 214 ', 220 ', 226 ', these images are used to create a log assembly that conjunction Into image 253,255,257.As mentioned above, such composograph 253,255,257 can be handled for The composograph 140 shown in display, such as display device 138 in Fig. 1, or for the exemplary electrical arc-welding in Fig. 1 Welding system 102 is automatically controlled.The type of power waveform 136 (Fig. 1) shown in exemplary exposure technology 200 in Fig. 2 It is periodicity power waveform 202.The example periodic power waveform 202 is sinusoidal, and this is easy to describe this exposure technique 200 principle, but pulse AC or DC electric power waveform, including the rise with customization or specialization, peak value, background and ending The signal of slope and amplitude, is also commonly used in many modern welding systems, and this exposure technique 200 is suitable for and can be used for Such pulse power waveform, as those skilled in the art should be understood that once after the principle that understanding of this technology.In figure Shown in 12A, 12B and 12C by this technology be applied to periodicity DC pulse power waveforms an example and will be under Text is more fully described.

In the time chart of Fig. 2 exemplary power waveform 202, the time (t) extends along abscissa (level) axle, and Voltage (V) is shown on longitudinal direction, the i.e. longitudinal axis.In this exemplary exposure technology 200, the single threshold on waveform 202 is used Threshold voltage level is (for example, starting trigger point 228,240,252,264,232,244,256,268,236,248,260 and 272 The exemplary electrical voltage levels at place) cause the photosensor array (Fig. 1) of camera 126 to from welding region 109 to start (triggering) The light for sending and reflecting exposes, and thus camera 126 obtains the original of welding region 109 or in welding region 109 special characteristic Beginning image, as explained below.Skilled in the art realises that the technology and implementation of electronic camera, therefore on The extension of the details of camera 126 (Fig. 1) is explained and is not essential for understanding this exposure triggering technique.As long as referring to following It is sufficient that content：The electronic camera expected has typically two-dimensional light sensor array (typically CMOS or CCD sensings Device), be frequently referred to photosensor array, the array to from object (for example, the spy in welding region 109 or welding region 109 Levy) send or reflect light exposure when by from the object luminous energy convert pixel arrays form original image (for example, Original image 204 ', 210 ', 216 ', 222 ', 206 ', 212 ', 218 ', 208 ', 214 ', 220 ', 226 '), in pixel battle array In column format, each pixel in pel array has the pixel value of electrical properties (for example, voltage, electric current, resistance etc.), institute Pixel value is stated to indicate in the luminous energy absorbed by each optical sensor in the photosensor array during exposing.Therefore, institute State photosensor array and produce the electronic pixel array with pixel value, these pixel values represent and send or reflect not from object Same luminous intensity.Such pel array can be handled to create the views picture of the object.Photosensor array pair The time for exposure for the light for sending or reflecting from object can be controlled by mechanical shutter, and the mechanical shutter physically beats aperture Open or close and close the desired period；Or controlled by shutter equivalent function, for example, pixel cell electric charge is electrically shifted Into covered doublet.Other electronic shutter equivalence techniqueses can also be used to start and terminate exposure period or light Can soak time section.Therefore, although when those skilled in the art can be by starting on opening and closing shutter and terminating exposure Between content understanding be the operation for also illustrating electronic shutter, but the description of more typically property is beginning and terminates exposure.Therefore, it is right It is equivalent in the explanation of shutter or shutter equivalent operation and can be used interchangeably.In fig. 2, illustrate multiple exemplary Exposure period 204,210,216,222,206,212,218,224,208,214,220 and 226.During these exemplary exposures Between section 204,210,216,222,206,212,218,224,208,214,220 and 226 have it is corresponding start trigger point 228, 240th, 252,264,232,244,256,268,236,248,260 and 272 and 230,242,254,266,234,246, 268th, the corresponding termination trigger point at 270,238,250,262 and 274.

In one example implementations of exemplary exposure technology 200 in fig. 2, in this example implementations Video system controller 124 for controlling camera 126 is connected to the source of welding current 122 (for example, via the link in Fig. 1 125) or on power waveform sensor 123 (for example, via link 148 in Fig. 1), to monitor the power waveform 136 in Fig. 1 In change electrical characteristic, such as voltage or levels of current, power waveform is sinusoidal electrical power waveform 202 in the example of figure 2. When detecting predetermined voltage or current threshold in power waveform 202, video system controller 124 is opened to the generation of camera 126 Beginning control signal, to start to cause the photosensor array in camera 126 to from welding region 109 or from welding region 109 In feature send or reflect luminous energy exposure.In fact, the threshold value can be voltage threshold, current threshold, impedance threshold, Or the other specification in power waveform 202, but for convenience and simplicity, when Fig. 2 chart is the voltage-contrast of power waveform 202 Between chart, it should be understood that it can also be another electrical characteristic.Correspondingly, as the voltage on power waveform 202 increases Greatly, it reach start threshold voltage level, for example start trigger point 228,240,252,264,232,244,256,268, 236th, the beginning threshold voltage level shown at 248,260 and 272.The video system controller detects when to reach that these are opened When voltage on beginning threshold voltage value and power waveform 202 starts in increase and as response to the generation of camera 126 Control signal, as described above.Detection, which starts threshold voltage level, to be completed by using simple comparison circuit, its In in video system controller 124 by the voltage detected with start threshold voltage value be compared, so as in power waveform Triggering generation beginning control signal when 202 voltages increase.User interface can be passed through in video system controller 124 128 easily set beginning threshold voltage level, so that user can be easily adjusted the beginning threshold voltage, or Person can provide the beginning threshold voltage with any other convenient mode.

Exposure period 204,210,216,222,206,212,218,224,208,214,220,226 in Fig. 2 is shown Photosensor array in camera 126 from the welding region 109 produced by welding process or from the light fixture supplied to sending Or the exposure period of the luminous energy exposure of reflection, as described in more detail below.As explained above, camera 126 is by corresponding The light of exposure period 204,210,216,222,206,212,218,224,208,214,220 and 226 period cameras 126 is passed The luminous energy that sensor array is absorbed produce corresponding original image 204 ', 210 ', 216 ', 222 ', 206 ', 212 ', 218 ', 208′、214′、220′、226′.By first group of four original image 204 ', 210 ', 216 ', 222 ' to be hereafter explained in more detail Mode is merged together to create the first composograph 253.Similarly, by second group of four original image 206 ', 212 ', 218 ', 224 ' are merged together to create the second composograph 255 in the same manner.Also by the 3rd group of four original images 208 ', 214 ', 220 ', 226 ' are merged together to create the 3rd composograph 257 in the same manner.Certainly, with welding The continuation of journey, video system controller 124 (Fig. 1) is always according to the extra original image establishment schematically shown in Fig. 2 with point n ' The extra composograph schematically shown in Fig. 2 with point N, so that as arc welding system 102 is as in Fig. 1 Shown in arrow 105 along workpiece 110,112 move and by composograph 253,255,257 ..., N streams create welding process Video.

As shown in Fig. 2 the first time for exposure of the first original image 204 ' used when creating the first composograph 253 Section 204 is that the first exposure period 206 of the first original image 206 ' with being used when creating the second composograph 255 is identical Time quantum and occur during the same phase of power waveform 202.Equally, used when creating three composographs 257 The first exposure period 208 of the first original image 208 ' be identical with both the first and second exposure periods 204,206 Time quantum and occur during the same phase of power waveform 202.Similarly, create corresponding composograph 253, 255th, 257 when the second exposure period 210,212,214 of original image 210 ', 212 ', 214 ' for using be also mutually the same And occur each other during the same phase of power waveform 202.Similarly, create corresponding composograph 253, 255th, 257 when the 3rd exposure period 216,218,220 of original image 216 ', 218 ', 220 ' that uses be also mutually the same And occur each other during the same phase of power waveform 202.Further, create corresponding composograph 253, 255th, 257 when the 4th exposure period 222,224,226 of original image 222 ', 224 ', 226 ' that uses be also mutually the same And occur each other during the same phase of power waveform 202.

As shown in Fig. 2 the exposure period 204,210,216,222 of corresponding original image 204 ', 210 ', 216 ', 222 ' Each of be all same threshold voltage level on power waveform 102, i.e. it is corresponding start trigger point 228,240, 252nd, start at 264, but they experienced power waveform 202, the larger rank of the longer period that extends across welding process Section.Therefore, the every independent original image 204 ', 210 ', 216 ', 222 ' used when creating the first composograph 253 is right Feature in welding region 109 (Fig. 1) or welding region 109 have gradually longer exposure period 204,210,216, 222.Identical principle is applied to the original image 206 ', 212 ', 218 ', 224 ' used when creating the second composograph 255 Exposure period 206,212,218,224 and create three composographs 257 when use original image 208 ', 214 ', 220 ', 226 ' exposure period 208,214,220,226.

As explained above, Fig. 2 show exemplary exposure technology 200 in, all exposure periods 204,210, 216th, 222,206,212,218,224,208,214,220,226 all detected in the rise of the voltage with power waveform 202 Start during to predetermined beginning voltage threshold level.Voltage in power waveform 202 is detected is increased to the predetermined beginning electricity When pressing threshold level, video system controller 124 starts trigger signal to the output of camera 126, and in response to this, camera 126 starts So that photosensor array exposes to the luminous energy for sending or reflecting from the feature (Fig. 1) in welding region 109, as explained above 's.Therefore, detected at the first beginning trigger point 228 it is such start voltage threshold cause video system controller 124 to The output of camera 126 starts control signal to start the first exposure period 204.Equally, start to examine at trigger point 240 second Measuring such voltage threshold that starts causes video system controller 124 to start control signal to start to the output of camera 126 Second exposure period 210；Such voltage threshold that starts is detected at the 3rd beginning trigger point 252 causes video system control Device 124 processed starts control signal to start the 3rd exposure period 216 to the output of camera 126；Start trigger point 264 the 4th Place detect it is such start voltage threshold cause video system controller 124 to the output of camera 126 start control signal so as to Start the 4th exposure period 222；Such voltage threshold that starts is detected at the 5th beginning trigger point 232 causes video system System controller 124 starts control signal to start the 5th exposure period 206 to the output of camera 126；Start triggering the 6th Such voltage threshold that starts is detected at point 244 causes video system controller 124 to start control signal to the output of camera 126 To start the 6th exposure period 212；Beginning voltage threshold as being detected at the 7th beginning trigger point 256, which is caused, to be regarded As system controller 124 to the output of camera 126 starts control signal to start the 7th exposure period 218；Start the 8th Such voltage threshold that starts is detected at trigger point 268 causes video system controller 124 to start control to the output of camera 126 Signal is to start the 8th exposure period 224；Such voltage threshold that starts is detected at the 9th beginning trigger point 236 to cause Video system controller 124 is set to start control signal to start the 9th exposure period 208 to the output of camera 126；The tenth Such voltage threshold that starts is detected at beginning trigger point 248 causes video system controller 124 to start to the output of camera 126 Control signal is to start the tenth exposure period 214；Such beginning voltage is detected at the tenth at the beginning trigger point 260 Threshold value causes video system controller 124 to start control signal to start the 11st exposure period to the output of camera 126 220；And such voltage threshold that starts is detected at the 12nd beginning trigger point 272 causes video system controller 124 Start control signal to start the 12nd exposure period 226 to the output of camera 126.As long as user want for welding into As continuing, this process is continued to.

Video system controller 124 also control the corresponding first to the 12nd exposure period 204,210,216,222, 206th, 212,218,224,208,214,220,226 and exposure period afterwards duration.Correspondingly, video system Some period of controller 124 after each exposure starts control signal generates and sent exposure eventually to camera 126 (Fig. 1) Only control signal, and as response, camera 126, which is terminated, causes photosensor array to sending or reflecting from welding region 109 Light exposure.As shown in Fig. 2 video system controller 126 be programmed to the termination trigger point 230 on power waveform 202, 242nd, 254,266,234,246,258,270,238,250,262,274 corresponding corresponding moment generated and sent out to camera 126 Send termination control signal, so as to terminate corresponding exposure period 204,210,216,222,206,212,218,224,208, 214、220、226.Video system controller 124 can be programmed to generate and send in the following manner described to camera 126 Exposure termination control signal：(i) to it is corresponding start trigger point 228,240,252,264,232,244,256,268,236, 248th, 260 and 272 trigger each exposure start time for being passed after control signal be subject to timing and it is each this Predetermined amount of time after the beginning control signal of sample is triggered generates the exposure termination control signal；(ii) electricity is determined When voltage in Reeb shape 102 matches with predetermined final voltage threshold value and generates institute when detecting such match State exposure termination control signal.The exposure termination control signal is generated for triggering the video system controller 124 Termination trigger point in such predetermined amount of time and the example and Fig. 2 of such predetermined final voltage threshold value on power waveform 202 230th, 242,254,266,234,246,258,270,238,250,262,274 is corresponding.Moreover, as explained above and such as Shown in Fig. 2, the original image 204 ', 210 ', 216 ', 222 ' for creating the first composograph 253 is different, for example gradually Longer, so that the sensor in photosensor array is in the minimum exposure time section for the first original image 204 ' In 204 by most strong luminous energy that the most bright feature (for example, electric arc 107 and plasma 108) of welding region 109 (Fig. 1) is sent and The possibility of saturation is caused to minimize, while so that the sensor in the photosensor array is for original image 222 ' The dark feature in welding region 109 is captured during most long exposure period 222 (for example, bead 103 and workpiece 110th, the possibility of some luminous energy 112) maximizes and also enhanced the created with intermediate exposure time section 210,216 Two and the 3rd original image 210 ' and 216 ' captures the feature for sending or reflecting moderate strength luminous energy (for example, electrode 106, weldering Connect molten bath 111, fusion zone 113) good view possibility.Equally, for the same reason, for creating the second composite diagram As 255 original image 206 ', 212 ', 218 ', 224 ' and for create the 3rd composograph 257 original image 208 ', 214 ', 220 ', 226 ' be different, is, for example, gradually longer.And, although exemplary exposure shown in Fig. 2 and merging Technology merges four original images to create every composograph 253,255,257, but can merge more or less than four originals These composographs of beginning creation of image.The aperture of camera 126 can also be changed and sensitive for some or all of exposure Degree, different characteristic or the portion of welding region 109 can be captured in available manner to strengthen during each exposure period The possibility divided.Furthermore, it is possible to become submerged plate 130 (Fig. 1) using optional dynamic, as explained below, to decay With the intensity for changing the luminous energy that camera 126 is reached from welding region 109, hence for for creating one or many of composograph The different characteristic or partial of welding region 109 can effectively be captured by strengthening the photosensor array for original image Possibility.

The original image 204 ', 210 ', 216 ', 222 ' caught by camera 126 is sent to video system controller 124, simultaneously And then merge to create the first composograph 253 by video system controller 124.Similarly, by camera 126 catch it is original Image 206 ', 212 ', 218 ', 224 ' is sent to video system controller 124 and is combined to create the second composograph 255, and original image 208 ', 214 ', 220 ', 226 ' is combined to the 3rd composograph 257 of establishment.Video system controller 124 create composograph 253,255,257 according to technology described below and as shown in Fig. 6 flow chart.Composite diagram As 253,255,257 be then displayed in user interface 128 and be stored in controller 124 in contained storage device or Elsewhere, so as to follow-up display and analysis and for changing the parameter of arc welding system 102 so as to improve its of weld seam The quality of his characteristic.Can also be shown with quick sequence a series of composographs 253,255,257 ..., N is so as in real time There is provided the video of welding process or for being stored and subsequently being watched.Composograph 253,255,257 can be used for machine Video and mode identification technology, to carry out automatic control in real time to arc welding system 102, as will be explained in greater 's.

Another exemplary progress exposure technique 300 is illustrated in Fig. 3, wherein start trigger point 352,364,376,388, 356th, 368,380,392,360,372,384,395 are prolonged after threshold value 303 exposure is detected on power supply wave shape 302 Slow.For convenience and it is compared, exemplary electrical source waveform 302 is analogous to the sinusoidal waveform in Fig. 2 shown in Fig. 3 202 sinusoidal waveform, but other kinds of waveform, such as pulse AC or DC waveforms can also be used for this technology 300, wrap Include to have and customize or specialized rise, peak value, background and ending slope and the special-shaped waveform of amplitude, such as many modern times welderings Commonly used in welding system.It is magnitude of voltage on power waveform 302 but it is also possible to be electricity that exposure in Fig. 3, which starts the example of threshold value 303, Other electrical characteristics in flow valuve, impedance value or power waveform 302 or associated therewith.Video system controller 124 is in electricity Detected at voltage threshold point 328,330,332,334,336,338,340,342,344,346,348,350 in Reeb shape 303 Exposure starts threshold voltage 303.However, instead of the spectrum assignment letter of triggering beginning immediately after beginning threshold voltage 303 is detected Number, video system controller 124 produces delay, and power waveform 302 relatively after stage, for example on the power waveform Beginning trigger point 352,364,376,388,356,368,380,392,360,372,384,395 at produce it is described start exposure Control signal.These start each of exposure control signal and are transferred to camera 126 to start to cause in camera 126 Photosensor array continue corresponding exposure period 304,310,316,322,306,312,318,324,308,314,320, 326 ground expose to the luminous energy that sends or reflect from welding region 109 (Fig. 1), thus produce corresponding original image 304 ', 310′、316′、322′、306′、312′、318′、324′、308′、314′、320′、326′.Video system controller 124 also to Camera 126 creates only exposure control signal of concurrently making arrangements for his funeral, so as in order to original image 304 ', 310 ', 316 ', 322 ', 306 ', 312 ', 318 ', 324 ', 308 ', 314 ', 320 ', 326 ' and terminate corresponding exposure period 304,310,316,322,306, 312、318、324、308、314、320、326.Explained as described above for Fig. 2 example, four original images 304 ', 310 ', 316 ', 322 ' are merged together to create the first composograph 397；Following four original images 306 ', 312 ', 318 ', 324 ' are merged together to create the second composograph 398；And following four original images 308 ', 314 ', 320 ', 326 ' are merged together to create the 3rd composograph 399.

What the same example as described above for Fig. 2 was explained, video system controller 124 is for creating the first composite diagram As 397 original image 304 ', 310 ', 316 ', 322 ' creates gradually longer exposure period 304,310,316,322.Together Sample, video system controller 124 is to be created for creating the original image 306 ', 312 ', 318 ', 324 ' of the second composograph 398 Build gradually longer exposure period 306,312,318,324, and create for create the 3rd composograph 399, gradually Longer exposure period 308,314,320,326.The first original graph for creating corresponding composograph 397,398,399 As 304 ', 306 ', 308 ' corresponding exposure period 304,306,308 has the mutually the same duration and in electric power Occur in same phase on waveform 302.Equally, for creating the second original graph of corresponding composograph 397,398,399 As 304 ', 306 ', 308 ' corresponding exposure period 304,306,308 has the mutually the same duration and in electric power Occur in same phase on waveform 302；The 3rd original image for creating corresponding composograph 397,398,399 316 ', 318 ', 320 ' corresponding exposure period 304,306,308 has the mutually the same duration and in electric power wave Occur in same phase in shape 302；And the 3rd original image for creating corresponding composograph 397,398,399 304 ', 306 ', 308 ' corresponding exposure period 322,324,326 has the mutually the same duration and in electric power wave Occur in same phase in shape 302.Correspondingly, for create the first composograph 397 this four original images 304 ', Corresponding terminating point 354 of 310 ', 316 ', 322 ' exposure period 304,310,316,322 on power waveform 302,366, 378th, terminate at 390；For the exposure for lower four original images 306 ', 312 ', 318 ', 324 ' for creating the second composograph 398 Terminated at corresponding terminating point 358,370,382,394 of the light period 306,312,318,324 on power waveform 302；And For create the 3rd composograph 399 lower four original images 308 ', 314 ', 320 ', 326 ' exposure period 308, 314th, terminated at 320, the 326 corresponding terminating point 362,374,386,396 on power waveform 302.

Therefore, by by the exposure period 204 in Fig. 2 examples, 210,216,222,206,212,218,224,208, 214th, 220,226 with Fig. 3 examples in exposure period 304,310,316,322,306,312,318,324,308,314, 320th, 326 it is compared, the original image for creating first, second, and third composograph 397,398,399 is used in Fig. 3 304 ', 310 ', 316 ', 322 ', 306 ', 312 ', 318 ', 324 ', 308 ', 314 ', 320 ', 326 ' go out in power waveform 302 The existing stage is with exposure period 204,210,216,222,206,212,218,224,208,214,220,226 in power waveform The stage occurred in 202 is different.The intensity and physics of the light produced in welding region 109 (Fig. 1) due to welding system 102 are special Levy and change with the voltage of the change associated with the power waveform, electric current or impedance, by camera 126 in Fig. 3 examples The original image 304 ', 310 ', 316 ', 322 ', 306 ', 312 ', 318 ', 324 ', 308 ', 314 ', 320 ', 326 ' of generation will be caught Grasp in welding region 109 with the original image 204 ' in Fig. 2 examples, 210 ', 216 ', 222 ', 206 ', 212 ', 218 ', 208 ', 214 ', 220 ', 226 ' different physical features and luminous intensity.Moreover, in Fig. 3 examples voltage threshold point 328,330, 332nd, detect at 334,336,338,340,342,344,346,348,350 exposure start threshold voltage, with actual beginning Retardation between trigger point 352,364,376,388,356,368,380,392,360,372,384,395 can be by video system Controller 124 unite come automatically or by being changed from being manually entered for user interface 128, it is described be manually entered be with Composograph 397 obtained by the observation of family, 398,399 ..., the different characteristic from the point of view of N in welding region 109 or in order to obtain use Family want composograph 397,398,399 ..., the desired image quality of feature observed in N and find optimal setting When make.

The exemplary constant exposure technique 400 for starting retardation with variable exposure is illustrated in Fig. 4, wherein for side Just and it is compared, sinusoidal electrical power waveform 402 is similar to the sinusoidal waveform 202 and 302 in Fig. 2 and 3 examples again.Fig. 4 perseverance Surely exposure example 400 is illustrated catches original image with constant exposure period, for example original image 404 ', 410 ', 416 ', 422 ', 406 ', 412 ', 418 ', 424 ', 408 ', 414 ', 420 ', 426 ', i.e. wherein, for original image 404 ', 410 ', 416 ', 422 ', 406 ', 412 ', 418 ', 424 ', 408 ', 414 ', 420 ', 426 ' exposure period 404,410,416,422, 406th, 412,418,424,408,414,420,426 all have the mutually the same duration but in power supply wave shape 402 Different piece or the stage.As Figure 4 shows, the first exposure period 404 extends across power supply wave shape 402 and is starting to trigger Part (stage) between point 428 and termination trigger point 430, at the beginning trigger point, video system controller 124 is transmitted Number to camera 126 to start so that the photosensor array in camera 126 exposes to the light for sending or reflecting from welding region 109 Light, and at the termination trigger point, video system controller 124 signals to camera 126 to terminate exposure.Video system System controller 124 can use (detection) threshold value, for example start voltage threshold at trigger point 428, so as to as being described above ground Trigger and start control signal to the exposure of camera 126 to start exposure.Equally, by setting for video system controller 124 The beginning voltage threshold that exposure starts control signal is generated for being triggered in those exposure starting points to camera 126, other exposures The light period 410,416,422,406,412,418,424,408,414,420,426 each can start exposure point accordingly 440th, start at 452,464,432,444,456,468,436,448,460,472.Due in this exemplary exposure technology 400 The duration of exposure period 410,416,422,406,412,418,424,408,414,420,426 is all mutually the same, Therefore video system controller 124 be configured to it is each it is corresponding exposure starting point 428,440,452,464,432,444, 456th, 468,436,448,460,472 come to generate exposure termination control signal to camera 126 afterwards with identical predetermined time amount. Correspondingly, corresponding termination trigger point 430 of the video system controller 124 on power waveform 402,442,454,466,434, 446th, 458,470,438,450,462,474 terminate these exposure periods 404,410,416,422,406,412,418,424, 408、414、420、426.Alternatively, camera 126 itself can have the default work(that exposure is terminated in scheduled exposure time section Can, so that these exposures need not be terminated from video system controller 124 to the exposure termination control signal of camera 126 Period 404,410,416,422,406,412,418,424,408,414,420,426.In a further alternative, video System controller 124 can use termination threshold voltage value terminate trigger point 430,442,454,466,434,446,458, 470th, to the trigger exposure termination control signal of camera 126 at 438,450,462,474.In any case, camera 126 is for every When one corresponding exposure period 404,410,416,422,406,412,418,424,408,414,420,426 is with identical It is each that the area of a room produces original image 404 ', 410 ', 416 ', 422 ', 406 ', 412 ', 418 ', 424 ', 408 ', 414 ', 420 ', 426 ' Person.However, due to these corresponding exposure periods 404,410,416,422,406,412,418,424,408,414,420,426 In some be to start under different threshold voltages on power waveform 402, therefore they are in the different piece of power waveform 402 Occur on (stage).This exemplary exposure technology 400 is shown as, and is started trigger point 428,432,436 and is in the first beginning electricity Threshold value is pressed, starts trigger point 440,444,448 and be in second to start voltage threshold, starts trigger point 452,456,460 and is in the Three start voltage threshold, and start trigger point 464,468,472 in the 4th beginning voltage threshold.Therefore, original image 404 ', 406 ', 408 ' have the identical time for exposure on the same Part I (stage) of power waveform 402；Original image 410 ', 412 ', 414 ' have the identical time for exposure on the same Part II (stage) of power waveform 402；Original image 416 ', 418 ', 420 ' have the identical time for exposure on the same Part III (stage) of power waveform 402；Original image 422 ', 424 ', 426 ' have the identical time for exposure on the same Part IV (stage) of power waveform 402；And electric power The first, second, third and fourth part (stage) of waveform 402 is different from each other.Therefore, it can by setting it is specific, Fixed time for exposure and the trigger exposure in the luminous intensity desired by welding generation, to control the light in photosensor array The saturation of sensor, because voltage generation higher in power waveform 402 brighter electric arc 107 and plasma 108, and electric power Relatively low voltage produces dark electric arc 107 and plasma 108 in waveform 402.

As mentioned above, the intensity for the luminous energy for sending and reflecting from welding region 109 and even welding region 109 Physical characteristic (for example, fusing, drop, plasma size, splash etc.) with the electrical characteristic of weld power waveform Change.Therefore, the weldering captured during the Part I (stage) by original image 404 ', 406 ', 408 ' in power waveform 402 Connect the luminous intensity in region 109, features and characteristics in some aspects with by original image 410 ', 412 ', 414 ' in power waveform 402 Part II (stage) during the luminous intensity, the features and characteristics that capture it is different, even if their exposure period 404, 406th, 408,410,412,414 it is identical be also such.Equally, power waveform 402 is being extended across not by other original images The luminous intensity of welding region 109 that is captured during exposure period with part (stage), features and characteristics are in some aspects To be different.

The explanation that is provided for the technology 200 and 300 in Fig. 2 and 3 similar to more than, corresponding exposure period 404, 410th, the original image 404 ', 410 ', 416 ', 422 ' that 416,422 periods obtained is combined to create the first composograph.Together Sample, the original image 406 ', 412 ', 418 ', 424 ' obtained during corresponding exposure period 406,412,418,424 is closed And to create the second composograph 478, and obtain original image during corresponding exposure period 408,414,420,426 408 ', 414 ', 420 ', 426 ' are combined to create the 3rd composograph 480.As long as user wants, these processes can be unlimited Ground is repeated to obtain the extra original image represented with point n ', so as to create the extra composograph represented with point N.Equally as above What text was explained, the aperture of camera 126, the sensitivity of the optical sensor in the photosensor array of camera 126 and optional change The dimmed amount of submerged plate 130 can be changed independently or in any combination realize multiple bright levels so that by Camera 126 produce original image these different pixels at least some insatiable hungers and/or be not dark.

As explained above, these create composograph, the composograph 253 of such as Fig. 2 examples, 255,257, Fig. 3 realities The composograph 397,398,399 of example and one of the target of composograph 476,478,480 of Fig. 4 examples be, can be with butt welding Connect special characteristic such as bead 103, soldering machine nozzle 104, electrode 106, the electric arc in region 109 (Fig. 1) and weld zone 109 107th, plasma 108, molten bath 111, workpiece 110,112 and drop 121 are subject to high-resolution imaging.In this way, these Composograph shows all different pieces of welding region 109 and there is provided the precious information of the quality on bead 103. Using such information, the parameter of welding process can be adjusted, to ensure the welding of high-quality.For example, workpiece 110, 112 with the electric current in the juxtaposed part of electrode 107 should produce enough heats to create the fusion zone 113 of molten metal, should Drop 121 is fused into from the distal end of electrode 107 and the drop is with minimum (if any) splash in an uniform manner It is deposited in welding pool 111, welding pool 121 should be enough liquid and energy and workpiece with sufficiently high temperature 110th, the fusion zone 113 in 112 is fused in the intersection of workpiece 110,112, and the bead 103 of gained should be smooth and uniform Without visible hole.In addition, the position of weld tip (invisible in nozzle 104) and corresponding ground electrode 106 must Must be correct, and drop 121 should drop or be deposited on the intersection or attached of workpiece 110,112 by solder joint Closely.By the way that weldment 110,112 (typically in welding region 109 dark) can be checked together in an image and bright Plasma, drop 121, molten bath 111 and other features much, it is possible to accurate in the intersection of weldment 110,112 Ground and with high quality characteristic formation bead 103.By adjust the sensitivity of the detector in camera 126, aperture openings and/ Or become submerged plate 130 using dynamic, it can obtain at least some original images to create unsaturated image with enough light quantities. Of course, it is possible to by lamp 134 (Fig. 1) be arranged on camera 126 on or other convenient positions so as to in background and welding region 109 Dark feature such as workpiece 110,112 or bead 103 provide additional illumination, for the additional illumination, foot can be collected Enough light quantities to be imaged background area, such as weldment 110,112.These targets and principle are applied also for by hereafter more detailed The composograph that the other technologies carefully discussed are created.

The exemplary variable exposure technique 500 with variable beginning trigger delay amount is illustrated in Figure 5.For convenience and Be compared, the power waveform 502 in Fig. 5 be shown as sine, similar to the power waveform 202 in the example of Fig. 2,3 and 4, 302、402.The part of example technique 400 that example technique 500 in Fig. 5 is similar to Fig. 4 is, original image 504 ', 510 ', 516 ', 522 ', 506 ', 512 ', 518 ', 524 ', 508 ', 514 ', 520 ', 526 ' ..., n ' as original image 404 ', 410 ', 416 ', 422 ', 406 ', 412 ', 418 ', 424 ', 408 ', 414 ', 420 ', 426 ' ..., n ' be equally in power supply wave shape Obtained during 502 different piece (stage).However, exposure period 504,510,516,522,506,512,518,524, 508th, 514,520,526 have the different duration, and exposure period 404,410,416,422,406,412,418, 424th, 408,414,420,426 is all identical.In example technique 500, preceding four exposure periods 504,510,516,522 With the different duration, i.e. exposure period 516 is longer than exposure period 510, the latter is longer than exposure period 504, then The latter is longer than exposure period 522.Equally, when exposure period 506,508 with the identical of exposure period 504 with continuing Between；Exposure period 512,514 has and the identical duration of exposure period 510；Exposure period 518,520 have with The identical duration of exposure period 516；And exposure period 524,526 has holds with the identical of exposure period 522 The continuous time.Such as other example techniques 200,300,400 in Fig. 2,3 and 4, start trigger point 528,546,552,564, 532nd, 544,556,568,536,548,550,572 and terminate trigger point 530,542,554,566,534,546,558,570, 538th, 550,562,574 can be by clock timing or by detecting the threshold voltage or other electrical characteristics of power waveform 502 To set up.Also as explained above for the example technique 200,300,400 in Fig. 2,3 and 4, by camera 126 corresponding The original image exposure period 504 ', 510 ', 516 ', 522 ' created during exposure period 504,510,516,522 is closed And to create the first composograph 576；Created by camera 126 during corresponding exposure period 506,512,518,524 Original image 506 ', 512 ', 518 ', 524 ' is combined to create the second composograph 578；And by camera 126 corresponding The original image 508 ', 514 ', 520 ', 526 ' created during exposure period exposure period 508,514,520,526 is closed And to create the 3rd composograph 578.Conjunction in composograph 253 in Fig. 2 examples 200,255,257, Fig. 3 examples 300 Composite diagram into the composograph 476,478,480 and Fig. 5 examples 500 in image 397,398,399, Fig. 4 examples 400 It can be formed by the process of the corresponding original image of any desired combination as 576,578,580.For example, can be based on next How close to saturation or each statistically to assess close to complete darkness each independent pixel from every independent original image is Independent pixel.Other technologies can be used, for example, pre-determined bit will be had in original image based on used particular exposure The pixel selection put into using in the composite image.For example, from the center of detector array picture can be selected in initial exposure Plain (if the exposure period is very short) and select picture from the outer peripheral areas of detector array during long exposure Element, so as to view background area.Substantial amounts of other technologies can be used for image anabolic process.

In another example implementations of example described above 2,3,4 and 5 technologies, above-described exposure is opened Beginning control signal and exposure termination control signal can be provided from the source of welding current 122 to camera 126, the alternative phase in such as Fig. 1 Machine control link 148 is indicated, rather than is provided by single video system controller 124.With video system controller 124 The feature and ability similar with ability for the feature that such signal is provided to camera can be built into the source of welding current 122 it In.In another implementation, the video system controller can receive the signal from the source of welding current 122 and response In such signal, to the generation of camera 126, these exposures start control signal and exposure termination control signal.Therefore, video system Controller 124 can be the integral part of the source of welding current 122.

Can with Fig. 2,3,4 with one embodiment that the example technique shown in 5 is used together, can be by electric power The frequency setting of power waveform 202 in waveform, such as Fig. 2 is such as 110Hz.Will of course, it is possible to be provided to power supply wave shape 202 Any desired frequency of the exposure period matched with application-specific is provided, and only for example provides 110Hz.At this In individual Fig. 2 examples, the composograph 253,255,257 of combination is in the substantially a quarter wound with the frequency of power supply wave shape 202 Build, this is the speed of 27 images substantially per second.The video of standard is 30 images (frame) substantially per second, and Blu-ray Disc is every 24 images of second, and live image is 25 images substantially per second.So, it is visual to create to use power supply wave shape 202 Change extraordinary video, the power supply wave shape is substantially 110Hz frequency in this example.

Fig. 6 A are image (such as composite diagrams created more than in the example of Fig. 2,3,4 and 5 that displaying is used to generate welding Picture) welding video and control system 100 exemplary operation flow chart 600.In step 602, welding video and control The controller 124 of system 100 is obtained for operating the welding video and the operating parameter of control system 100.Video system control Device 124 processed can read these parameters from storage device.In computer systems, such storage device can be RAM or Disk storage equipment such as EEPROM or the similar storage device for hardware implementation mode.User interface 128 can be used for These operating parameters are provided.In one embodiment, video system controller 124 can include all-purpose computer, described general Computer can store the permission welding video with control system 100 to operate in different modalities so as to produce different images A series of different operating parameters.For example, illustrating different operator schemes or technology in figs. 2-5.In this context, scheme 2nd, the example technique 200,300,400,500 in 3,4 and 5 is also referred to as operator scheme.It is, of course, also possible to select other to operate Pattern.In other embodiments, one or two kinds of operator schemes may be only existed, and system can be preloaded with operand According to.For example, in the manual embodiment of welding video system 1000 shown in Fig. 10, the operating parameter of system can be loaded into firmly In part such as EEPROM or similar storage devices and it is accessed by a processor to obtain the data and according to disclosed herein Be the same as Example or technology do not operate the welding video system 1000.For example, in Figure 10 manual welding video system 1000 In embodiment, the video system controller 124 in Fig. 1, which can be encapsulated in, to be installed on the helmet 1002 or other facilitate position In simple miniaturized electronics bag 1008.Electronic equipment bag 1008 includes EEPROM memory device or contains operating parameter Other similar storage devices, microprocessor, state machine and other electronic equipments.Additionally or alternatively, can be in small electrical Use can provide the field programmable gate array of only a kind of or possible two kinds of different operator schemes in sub- equipment bag 1008 And other logic circuits (FPGA).

Referring again to Fig. 6 A, once obtain for operating the welding video and the operating parameter of control system 100, mistake Journey just proceeds to step 604 to select one group of operating parameter from some different operator schemes.Again, if merely with single Operator scheme, such as, then can be with cancellation step 604 in Figure 10 manual embodiment of welding video system 1000.Process is then In step 606 the system, including camera 126 are operated using these operating parameters.The operation of camera 126, including setting Different exposure period, aperture, sensitivity and optional dynamics become submerged plate 130 and associated with generation composograph Logic, performed by video system controller 124.In step 608, the original of welding region 109 is generated by camera 126 Image.By in the manner described above by the seizure of original image and power supply wave shape synchronously by these original images and welding Process is synchronous.In other words, by camera 126 in response to power waveform generates original image in the manner described above.So, phase After original image synchronous with power waveform there is phase with the chronological of welding process in an optimized fashion so as to producing Synchronous original image stream, to catch the spy in welding region 109 in the way of sufficiently fast and composograph stream can be created Determine feature, these composographs show all or specific spies in welding region 109 with the progress of welding process in real time Levy.Correspondingly, these images not rebound and there is provided to each feature as in welding process, it occurs in chronological order Differentiation continual and steady view.

With continued reference to Fig. 6 A, in step 610, composograph combination is regarded to create the substantially real-time of welding process Frequently.In this regard, composograph is simply according to for being combined to image to create desired composograph with them Any desired method shown the speed that creates, to provide the real-time video of welding process.Figure 9 illustrates For hardware implementation mode that original image is combined into composograph an example and be explained below.Depending on frame Speed, can use hardware or software realization mode to combine original image.In step 612, composograph is shown as regarding Frequently.Composograph can also be analyzed automatically or by observer, to determine whether that any welding parameter should be changed Become.For example, these composographs can be checked to determine, whether the position of weld tip and electrode should be changed, Huo Zhe electricity Whether the voltage or electric current of Reeb shape or the speed of weld tip should be changed.Other parameters can also be changed.

Also as shown in Figure 6A, can be by the system of automation, for example with and without some form of pattern-recognition Machine video system, depending on that will weld or which aspect of welding process is used for this alanysis, come described in checking and/or analyze Video.Machine video and mode identification technology are developed, are commercially available, such as MATLAB (trade mark) software well The pattern-recognition storehouse of platform.For example, bead 103 (Fig. 1) shapes and sizes of itself provide it is relevant with welding quality a large amount of Information.Machine video or mode identification technology can be used to observe and analyze the formation of the welding drop 121 in welding process And the development of welding pool 111, to change the curtage of the power waveform produced by the source of welding current 122.In welding During the size and location of drop 121 that the is formed and deposition of these drops 121 can be provided and welded in welding process Tip is connect relative to the related modification in the position of workpiece 110,112 and interval.Welding electrode 106 is relative to workpiece 110,112 Image also allow for position in an automated manner to change weld tip and electrode 106.In this regard, moreover it is possible to certainly The mode of dynamicization come observe and change weld tip and electrode 106 from workpiece 110,112 or from welding pool 111 with a distance from. In welding wire moves back and forth electric arc welding, move back and forth into an electrode 106 and form drop with the distal end of silk electrode 106 121 and move up away from welding pool 111 and then move downward and deftly deposit to the drop 121 formed In molten bath 111, therefore machine video and pattern-recognition can be used to monitor the process and adjust automatically electric power wave parameter Number and silk electrode 106 move back and forth parameter, to ensure drop formation completely and to be separated with silk electrode 106, only directly to molten In pond 111 and less than the top of molten bath 111.As another example, mode identificating software can be designed to detect welding pool Light transmitting, light transmitting around 111 show the fusion zone 113 of the weldment 110,112 around molten bath 111.This A little fusion zones 113 will be used as the bending area appearance for the light for sending the edge for being located just at molten bath 111.Again, this light hair The presence penetrated and the intensity of the transmitting are determined for the quality of weld seam 103.Furthermore, it is possible to use machine video technology To determine the height and width of bead 103 and welding process is adjusted, for example, change electric current or change welded header Speed or position, to obtain the bead 103 of desired size and shape, the uniformity etc..Such machine video and pattern are known Other function can be applied to synthesis by the video system controller 124 for being loaded with machine video and application of pattern recognition and parameter Image.When authenticated welding using the video system controller 124 of such machine video and mode identification procedure to composograph During the need for adjust condition or feature when, video system controller 124 outputs signal to the source of welding current 122 or robot System controller 142 or the two, so as to change need change parameter or condition.For example, from video system controller 124 to weldering The waveform control signal for connecing power supply may cause to any electrical parameter that the source of welding current 122 adjusted or changed power supply wave shape 136, for example Voltage, electric current, frequency, modulation, shape (rise, peak value, background and ending slope and, amplitude etc.), impedance or other characteristics. Position control signal from video system controller 124 to robot system controller 142 may cause to robot system control Device 142 outputs signal to robot system actuator, so as to for example by appropriate mechanical linkage 146, for any spy Determine welding job and depend on the type of welding and the type of workpiece by the tip in soldering machine nozzle 104, nozzle and electrode 106 Moved in any direction and be moved to any orientation or orientation relative to weldment 110,112.It is such that there is difference The robot welding system of actuator 144 and linkage 146 and robot system controller with control software and firmware System is well-known and commercially available.Alternatively, the robot controller software may be implemented within video system control In device 124 processed.Can also be by automatically analyzing and adjusting welding to composograph application machine video and mode identification procedure The other specification of process.Alternatively, in simpler implementation, video system controller 124 can pass through display device 138 or some other single alarms notify system (not shown), in machine video and the pattern knowledge applied to composograph Alarm or notice are exported when condition or feature that other process is adjusted the need for identifying in welding process.

Fig. 6 A process next proceeds to step 614, now determines whether to utilize different to the imaging system Operator scheme.To select different patterns by user, such as technology 200,300,400 or 500 shown in Fig. 2,3,4 or 5 or Another technology can, or this process can determine in an automated manner.For example, first operator scheme may not butt welding Connect dark feature, such as bead 103 or workpiece 110,112 in region 109 (Fig. 1) and sufficiently restriction or available information are provided. This determination can be carried out by the video simply checked these composographs or made with composograph, or can be led to The bright level for the pixel crossed around machine video measurement composograph is automatically determined or other automation process.Institute Stating the different operation modes of welding video and control system can pass through by longer exposure period or as explained above The exposure period for extending across the different piece (stage) of power waveform is caught to provide darker area preferably illumination or light Catch.In another example, the image saturation in the region around weld tip, at such as electrode 106 or in plasma 108 can Can provide to those features or formed on the distal end of electrode 106 or the drop that is deposited in welding pool 111 121 picture rich in detail.In this case, it is possible to select preferably to arrange the original image of those features to create The different operation modes of composograph.Again, some exemplary mode of operation are illustrated by the technology in Fig. 2-5.Can be Video system controller 124 presets these patterns so that the video system controller uses the ginseng of these patterns automatically Manifold, or operator scheme come logging data can be changed by user interface 128.If it is determined that should be regarded to welding As from control system 100 use different operator schemes, then the process in Fig. 6 A be back to step 604, in the step from One group of operating parameter is selected in some different modes, or simply by pattern typing user interface 128.In this regard, use Default pattern can be stored and be applied in welding video and control system 100 by family interface 128.

If determining to advance to without using different mode, process in the step 614 of the flow chart shown in fig. 6 Step 616, determine whether weld seam is satisfactory in the step.If weld seam is satisfactory, process is back to step 612 so that can continue to show and analyze video.If determining that weld seam is unsatisfactory in step 616, process is advanced to Step 618, welding system parameter is changed in the step.Process then returns to step 608, and warp is generated in the step The composograph of the welding process of adjustment.

Fig. 6 B are the flow charts 650 for the exemplary operation for showing video system controller 124.Step shown in Fig. 6 B can To be performed by computing system, embeded processor or logic hardware such as field programmable gate array (FPGA).As draped over one's shoulders in Fig. 6 B Dew, video system controller 124 reads the threshold value of power supply wave shape in step 652.Video system controller 124 is then in step The retardation (if any) associated with one or many exposures is read in rapid 654, as disclosed in Fig. 2-5.In step In 656, the controller reads exposure period.All these data can be stored in RAM or ROM storage devices or hard In part implementation, in EEPROM or in other storage devices.If exposure period is not provided with clock pulses, Video system controller 124 can calculate the clock pulses quantity exposed every time in step 658.In step 660, video system The system reading detector sensitivity data of controller 124.As described above, the detector of the photosensor array in camera 126 There can be adjustable sensitivity.The sensitivity of these detectors can be adjusted to for being incident on the light in camera 126 Light on sensor array is more sensitive or more insensitive.The data on sensitivity can be stored for each exposure period, As shown in Fig. 2-5, so that changing sensitivity for each exposure period.Alternatively, institute can be directed to There is exposure period to select single sensitivity.In step 662, video system controller 124 reads aperture data.It can be directed to Each exposure period changes aperture data, to adjust the amount for the light being incident on the photosensor array of camera 126. In step 664, video system controller 124 starts control signal to the generation exposure of camera 126, to start so that the light is passed Sensor array exposes to the luminous energy for sending or reflecting from welding region 109.Exposure for starting exposure starts control signal can To be in response to reach threshold value or in response to prolonging from power waveform reaches threshold value as explained above in weld power waveform Measure and generate late.In step 668, when having reached the clock pulses quantity for each exposure period, video system Controller generates exposure termination control signal to camera 126, to terminate so that the photosensor array is to from welding region The 109 luminous energy exposures for sending or reflecting.Alternatively, exposure termination threshold value can be used to trigger to the generation of camera 126 exposure eventually Only control signal.In step 670, generated according to the sensitivity data and aperture data of the reading of video system controller 126 For adjustment sensitivity and the control signal of aperture.It is also possible to generate the control signal for each exposure period. In step 672, the control signal is applied to camera 126.Camera 126 adjusts all then according to the control signal Parameter.In step 674, for the every original image produced during each exposure period, the picture number from camera 126 Received according to by video system controller 124.In step 676, video system controller 126 using different logic functions by this A little independent images are combined into composograph.Moreover, these logic functions can be for these independences in every group of image are former The pixel of every image is combined to any desired logic function of the composograph desired by acquisition in beginning image.In step In rapid 678, show these composographs to check.

Fig. 7 is illustrated for starting so that the photosensor array of camera 126 is to from welding region 109 sending or reflecting The example system 700 of luminous energy exposure.As shown in fig. 7, power waveform 704 and threshold value 706 are applied into comparator 702.Than The amplitude of the electrical characteristic of power waveform 704 such as voltage and threshold value 706 are compared compared with device 702.When the values match, The generation exposure of comparator 702 starts trigger signal 708.Then apply exposure to delay counter 710 and start trigger signal.It is described Delay counter is counted to clock pulses quantity 712 (if any), until reaching length of delay 720.Delay counter 710 then generate trigger signal 714.Trigger signal 714 is applied to control signal generator 716, the control signal occurs Device generates the control signal 718 for being applied to camera 126.Certainly, system shown in Fig. 7 can be without delay counter 710 Run on ground.Delay counter 710 provides more flexibilities, especially when that can change length of delay 720.Modified delay Value 720 can be used in different operation modes of the welding video with control system 100.

It is in succession former by multigroup four in some way in exemplary mode of operation (technology) shown in Fig. 2,3,4 and 5 Beginning image is combined into composograph.For example, it is described above, preceding four original images 204 ', 210 ', 216 ', 222 ' are entered Row combines to create the first composograph 253.Repeat this anabolic process and follow-up original image is combined into composograph. Four original images are combined to create a composograph although showing in the example of Fig. 2,3,4 and 5, can be used Any amount of original image creates composograph.The electronic values produced by the standalone sensor of two-dimensional sensor array are given birth to The domain of pixel light intensity value as image, and generally scanned with domain, for example the domain is read line by line it is a series of individually Pixel data value read out from the photosensor array, typically since the pixel value in a turning in domain simultaneously And last pixel value carried out line by line into the opposite corners in the domain.Schematically showing in fig. 8 to use In by from for merging the example system that the respective pixel for this four original images for being combined into image is alignd in time. As shown in figure 8, using three shift registers 810,812 and 814 come by from one group of four original for creating composograph First, second, and third original image in beginning image is (for example, the original image for creating the composograph 253 in Fig. 2 204 ', 210 ', 216 ') the respective pixel value in respective pixel stream 802,804,806 is used to create the composite diagram with coming from The pixel stream 808 of the 4th original image (for example, original image 222 ' for creating the composograph 253 in Fig. 2) of picture exists Alignd on time.Effectively, first three phase for opening each image in original image (for example, original image 204 ', 210 ', 216 ') Pixel stream is answered progressively to be postponed by corresponding shift register 810,812,814 in time so that they and the 4th image (example Such as, original image 222 ') pixel stream align in time.When the correspondence of this four pixel streams from this four original images When pixel value aligns in time, they can undergo assessment and selection course is come from this four original images (for example, original graph As 204 ', 210 ', 216 ', 222 ') in selection will be used to create the specific of composograph (for example, composograph 253 in Fig. 2) Pixel value, as will be explained in greater.

As shown in Figure 2, original image 204 ' is by the establishment completely of camera 126 when exposure termination trigger signal 230 , and original image 222 ' is created completely when exposure termination trigger signal 266 by camera 126.In other words, corresponding Time point 230,266 completes exposure for every original image 204 ', 222 ', and at corresponding time point 230,266, camera 126 transmit the pixel stream for these original images 204 ', 222 '.Therefore, the pixel value of original image 204 ' must be delayed by Time quantum between exposure termination trigger point 230 and exposure termination trigger point 266.Determine two exposure termination trigger points 230, Clock pulses quantity between 266, and the quantity of the shift unit is provided to shift register 810 so that first is original The pixel stream 802 of image 204 ' is delayed by the time quantum.When the serial pixel stream 802 enters in shift register 810, Pixel data is pushed to output 820 by clock pulses 816 by shift register 810.

Similarly, the second pixel stream 804 from the second original image (for example, original image 210 ') is delayed by making a reservation for Amount.In this example, retardation is equal to the original image of exposure termination trigger point 242 and the 4th of the second original image 210 ' Time quantum between 222 ' exposure termination trigger point 266.Shift register 812 causes from the in response to clock signal 816 The pixel data stream 804 of two original images 222 ' is shifted through the shift register.Element number in shift register 812 Equal to the clock pulses quantity between exposure termination trigger point 242 and exposure termination point 266.Pixel stream 806 in Fig. 8 is by What three original images (for example, original image 216 ' in Fig. 2) were produced.Shift register 814 is in response to clock signal 816 by institute Serial pixel stream 806 is stated to shift.Pixel stream 808 from the 4th original image is not shifted by register delay.Pixel stream 802, 804th, 806 all align in time with pixel stream 808.Therefore, output 820,822,824,826 includes what is alignd in time Output 818.In other words, one group of original image an of combination image (for example, first composograph 253 in Fig. 2) will be formed In this four original image (for example, original image 204 ', 210 ', 216 ', 222 ' in Fig. 2) in the corresponding picture of each Element aligns in time at output 818.In this way, it is possible to by every original image in every group of original image The pixel value of respective pixel be compared, so that selection will be used to create the combination image from corresponding every four pixels Single pixel value.Fig. 8 alignment means are may not be needed in digital computing system implementation, because such system In pixel can be stored together with address, and can be compared based on address location.

Fig. 9 is the schematic presentation of an exemplary embodiment of image combiner 900.Output 820 from Fig. 8, 822nd, this four of 824,826 different pixel streams (being alignd in time at Fig. 8 output 818) are applied to Fig. 9 Image combiner 900 and accordingly include the first image pixel stream 902, the second image pixel stream 904, the 3rd image pixel The image pixel stream 908 of stream 906 and the 4th.Correspondingly, these independent original images (for example, original image 204 ' in Fig. 2, 210 ', 216 ', 222 ') each of constitute for creating composograph (for example, first composograph 252 in Fig. 2) One group of four original image.Can be by selecting pixel value from the pixel stream of this four different original images, using figure Composograph is created as combiner 900.Pixel stream 902 from the first original image (for example, original image 204 ') is applied Add to saturation degree comparator 926 and darkness comparator 934.There is each pixel of first pixel stream 902 instruction to illuminate original graph The brightness of the incident radiation of the pixel of picture or the digital value of intensity.The digital value is compared with intensity value 910 To produce residual quantity signal 942, the residual quantity signal designation intensity value 910 with it is from welding region 109 (Fig. 1), work as camera The luminous energy in the pixel is incident on when 126 photosensor array from the luminous energy that welding region 109 is sent or is reflected to exposing Brightness or intensity between difference.The difference signal 942 is applied to saturation difference comparator 958.In pixel stream 902 Each pixel be also applied to darkness comparator 934, the darkness comparator is by the brightness of each pixel in pixel stream 902 Digital value is compared with opacity value 918.Opacity value 918 may simply be zero, or it may be constructed certain selected by user Individual other values.Intensity value 910 and opacity value 918 can be inputted by user by user interface 128.Or, these saturations Angle value and opacity value can be stored in saturation degree comparator 926 and darkness comparator 934.Opacity value 918 will be indicated with coming When photosensor array from welding region 109, when camera 126 exposes to the luminous energy for sending or reflecting from welding region 109 The difference signal 950 of difference between the intensity for the luminous energy being incident in the pixel applies to darkness difference comparator 962.

Similarly, the second pixel stream 904 of the second original image is applied to saturation degree comparator 928 and darkness comparator 936.Pixel value in the pixel stream 904 and intensity value 912 and opacity value 920 are compared to produce saturation difference Signal 944 and darkness difference signal 952.The saturation difference signal 944 is applied to saturation difference comparator 958.Institute State darkness difference signal 952 and be applied to darkness difference comparator 962.

Equally, the 3rd pixel stream 906 of the 3rd original image is applied to saturation degree comparator 930 and darkness comparator 938.Saturation degree comparator 930 produces the saturation difference signal 946 for being applied to saturation difference comparator 958.It is described full It is the incidence of the pixel in the photosensor array during the camera 126 is illuminated during exposing with degree difference signal 946 Difference between the intensity and intensity value 914 of radiation.Pixel stream 906 is also applied to darkness comparator 938, the darkness ratio Compared with device by the intensity of the incident radiation of the pixel in the photosensor array during the camera 126 is illuminated during exposing with Opacity value 922 is compared, to produce the darkness difference signal 954 for the darkness difference comparator 962 being applied to.

Equally, the 4th pixel stream 908 of the 4th original image is applied to saturation degree comparator 932 and darkness comparator 940.Saturation degree comparator 932 produces the saturation difference signal 948 for being applied to saturation difference comparator 958.It is described full It is the incidence of the pixel in the photosensor array during the camera 126 is illuminated during exposing with degree difference signal 948 Difference between the intensity and intensity value 916 of radiation.Pixel stream 908 is also applied to darkness comparator 940, the darkness ratio Compared with device by the intensity of the incident radiation of the pixel in the photosensor array during the camera 126 is illuminated during exposing with Opacity value 924 is compared, to produce the darkness difference signal 956 for the darkness difference comparator 962 being applied to.

Intensity value 910,912,914,916 and opacity value 918,920,922,924 can be solid for specific system Fixed, or they can be manually or automatically adjustable with machine video technology.

In figure 9 a in a shown example, the composograph 253 in Fig. 2 be by four original images 204 ', 210 ', 216 ', 222 ' merging, as explained above.It is same as explained above, this four original images 204 ' in Fig. 2,210 ', 216 ', 222 ' are created by camera 126 with gradually increasing exposure period 204,210,216,222.Therefore, camera 126 In photosensor array in pixel optical sensor there is gradually increased exposure period 204,210,216,222, in institute State and absorbed in exposure period from the special characteristic in welding region 109 (Fig. 1), for example from bead 303, soldering machine nozzle 104, weldering Machine electrode 106, electric arc 107, plasma 108, welding pool 111, workpiece 110,112, fusion zone 113 and drop 121 are sent out The light for going out or reflecting.Some (for example, electric arc 107 and plasmas 108) in these features are than other features (for example, electrode 106th, welding pool 111, drop 121 and fusion zone 113) it is slightly brighter and than other other features (for example, bead 103rd, soldering machine nozzle 104 and workpiece 110,112) much brighter.Therefore, from most bright feature (for example, from electric arc 107 and wait from Daughter 108) send or the luminous energy that reflects has and bigger gathers in the photosensor array of camera 126, such strong luminous energy The possibility of burnt specific optical sensor or detector saturation thereon, and the relatively weak light energy from dark feature is less likely to make Specific optical sensor or the detector saturation in the photosensor array of camera 126, such focused on compared with weak light energy thereon. The optical sensor or detector of saturation are not produced for the available pixel data of image.Therefore, in order to from the light sensing of camera 126 These optical sensors or detector that in device array, most strong luminous energy is focused on thereon obtain available pixel data, it is necessary to limit Make the exposure of these optical sensors or detector to such strong luminous energy.On the other hand, if from dark feature (for example, from weldering Pearl 103 and workpiece 110, the luminous energy 112) reflected do not have enough energy to be used to focus in camera 126, such low luminous energy Optical sensor or detector thereon produces the available pixel data of these dark features, then gained original image in these Pixel will not show these dark features.Therefore, longer exposure period may can make the optical sensor battle array of camera 126 In row, such optical sensor or detector focused on thereon compared with weak light energy is detected from the enough of these dark features Luminous energy, thus enables these optical sensors or detector produce the available pixel data of these dark features.Therefore, Fig. 2 is real The target of gradually longer exposure period 204,210,216,222 in example is in order that the photosensor array of camera 126 In, most strong luminous energy from most bright feature focus on specific optical sensor or detector thereon in shorter exposure period Period (for example, first and second exposure periods 204,210 during) produces available pixel data and unsaturated, although weaker The optical sensor or detector that luminous energy focuses on thereon can not produce available pixel data during these shorter exposure times section. Then, (for example, in the period of the third and fourth exposure period 216,222, camera during subsequent longer exposure period The optical sensor or detector that in 126 photosensor array, from dark feature relatively weak light energy focuses on thereon may Available pixel data can be produced, although optical sensor or detector that most strong luminous energy focuses on thereon are probably saturation.Phase Ying Di, if parameter is (for example, aperture, transducer sensitivity and the optional decay (figure using optional change submerged plate 130 1)), then the first original image 204 ' from minimum exposure time section 204 in Fig. 2 examples, which will have, comes from most bright feature (example Such as, electric arc 107 and plasma 108) available pixel, and each successive subsequent original image 210 ' in Fig. 2 examples, 216 ', 222 ' can have more come self-saturating optical sensor or detector thus useless pixel, but also have From the optical sensor or the more available pixel of detector for dark feature (for example, bead 103 and workpiece 110,112). It is medium strong from somewhat bright features (for example, nozzle 104, electrode 106, molten bath 111, fusion zone 113 and drop 121) Degree luminous energy may be at the light of moderate strength luminous energy focusing make in the photosensor array of camera 126, such thereon and pass Sensor or detector can be in the middle scopes for producing available pixel of some or all of original image 204 ', 210 ', 216 ', 222 ' It is interior.

The purpose of image combiner 900 in Fig. 9 be from the original images 204 ' of Fig. 2 example techniques 200,210 ', 216 ', 222 ' appropriate pixels of middle selection and merging produce composograph 253, and the composograph, which has, to be clearly showed that It is in welding region 109 (Fig. 1), be user for specifically check, analyze or control purpose and desired one, some or institute There is the pixel of feature.Certainly, the purpose is applied to other example techniques described herein and original image.In combiner In 900 exemplary application, graphically illustrate in figure 9 a in original image 204 ', 210 ', 216 ', 222 ' Any pixel value 980,981,982,983 of corresponding any respective pixel, just as them in fig .9 with first, second, the What the three and the 4th image pixel stream 902,904,906,908 occurred.Pixel value in the figure is higher, it is meant that brighter, but Brightness, the specific unit of optical power density are not used to this displaying.In this Fig. 9 A example, the saturation degree of all four in Fig. 9 The intensity value 910,912,914,916 of comparator 926,928,930,932 is set to mutually the same, but they can not Together.Similarly, in Fig. 9 the opacity value 918,920,922,924 of all four darkness comparators 934,936,938,940 at this It is set to mutually the same in Fig. 9 A examples, but they can be different.When there is most short exposure due to the first original image 204 ' Between section (Fig. 2), the pixel value 980 of the pixel in the original image 204 ' is possible to and second, third and the 4th original image The gradually higher pixel value 981,982,983 of respective pixel in 210 ', 216 ', 222 ' is compared to lower, as explained above.

When in the saturation degree comparator 926,928,930,932 in Fig. 9 will from original image 204 ', 210 ', 216 ', When 222 ' pixel value 980,981,982,983 is compared with intensity value 910,912,914,916, the saturation degree of gained is poor Xor signal 942,944,946,948 is gradually smaller, as shown in Figure 9 A.In this example, from the 4th original image 222 ' Pixel value 983 is shown as satisfying by creating the lasting long exposure period 222 (Fig. 2) of the 4th original image 222 ' With this high-strength light energy in the very bright feature (for example, electric arc 107 or plasma 108) in welding region 109 May in the case of focusing on in the photosensor array of the camera 126, optical sensor of the generation pixel or detector Occur.Therefore, as shown in Figure 9 A, the saturation difference for the gained of the pixel value 983 in the 4th original image 222 ' is believed Numbers 948 be zero, and this shows that the pixel in the 4th original image 222 ' is unavailable.On the other hand, respectively for first, second The saturation degree of the non-zero obtained with the respective pixel in the 3rd original image 204 ', 210 ', 216 ' from pixel value 980,981,982 Difference signal 942,944,946 shows that any one in these three pixel values 980,981,982 is all potentially available for composite diagram As 253 (Fig. 2), this wishes what kind of brightness, contrast or other picture characteristics depending on gained composograph 253.

With continued reference to Fig. 9 A, when in the darkness comparator 934,936,938,940 in Fig. 9 will from original image 204 ', When 210 ', 216 ', 222 ' pixel value 980,981,982,983 is compared with dark and angle value 918,920,922,924, gained Darkness difference signal 950,952,954,956 it is gradually smaller.In this example, the pixel from the first original image 222 ' Value 980 is shown as by creating lasting short exposure time 204 (Fig. 2) of section of first original image 222 ' but dark Color, this can be focused in the low intensity light of the dark feature (for example, weld seam 103 or workpiece 110,112) in welding region 109 It is likely to occur in the case of in the photosensor array of the camera 126, optical sensor of the generation pixel or detector. Therefore, as shown in Figure 9 A, the darkness difference signal 950 for the gained of the pixel value 980 in the first original image 204 ' is Zero, this shows that described pixel in the first original image 204 ' may be unavailable, except non-user be indifferent in welding region compared with Whether dark feature is visible in specific composograph 253.For example, user or automatic machinery video system may be only to drops 121 is interested, and drop is not usually one of most dark feature, in the case, and the pixel value 980 is probably available.Separately On the one hand, respectively for the respective pixel in second, third and the 4th original image 210 ', 216 ', 222 ' from pixel value 981, 982nd, the darkness difference signal 952,954,956 of 983 obtained non-zeros shows, appointing in these three pixel values 981,982,983 One is all potentially available for composograph 253 (Fig. 2), and this wishes what kind of brightness, contrast depending on gained composograph 253 Degree or other picture characteristics.

However, because the respective pixel as explained above from the 4th original image 222 ' is unavailable due to saturation, And because the respective pixel from the first original image 204 ' as explained above is dark, then in this example only from the The respective pixel value 981,982 of two and the 3rd original image 210 ', 216 ' can be used for showing weld zone in composograph 253 Domain 109 (Fig. 1) is illuminated feature.Certainly, across the power waveform other parts (stage) other exposure periods, its His photosensor array sensitivity setting, the setting of other apertures, other optical attenuations, additional illumination and other adjustment can be Each pixel provides different results.It is possible that by being dynamically changed during exposure period such as exposure period, exposure Across stage of power waveform, sensor array sensitivity setting, aperture setting, optical attenuation, additional illumination and other tune The parameter of whole grade, can keep most of in the respective pixel value of original image or even be entirely below saturation and higher than dark Color.

Also as described in Figure 9, bright value range 960 is applied to saturation difference comparator 958.Similarly, dark value range 964 It is applied to darkness difference comparator 962.Saturation difference signal 942,944,946,948 is also applied to saturation difference ratio Compared with device 958.Saturation difference comparator 958 saturation difference signal 942-948 is compared and in one embodiment, Select the maximum saturation difference signal fallen into the range of value range 960.Therefore in the output of saturation difference comparator 958 The selected saturation degree pixel value that clearly pixel 966 has in place is farthest from the intensity value but still falls within bright value range 960 Within.Correspondingly, the pixel selected from this four different pixels streams is undersaturated pixel but the pixel value that has can be with It is shown and checks in the composite image.In Fig. 9 A examples discussed above, bright value range 960 can be configured to provide such as Bright scope 960 ' shown in Fig. 9 B.Therefore in this example, the pixel value 980 from the first original image 204 ' due to less than Bright scope 960 ' and be rejected, and the pixel value 983 from the 4th original image 222 ' due to higher than bright scope 960 ' by Refusal.From corresponding second and the 3rd original image 210 ', 216 ' the two pixel values 981,982 between, from second The saturation difference signal 944 that the pixel of original image 210 ' has is more than the saturation of the pixel from the 3rd original image 216 ' Spend difference signal 946.Therefore, according to test explained above, saturation difference comparator 958 (Fig. 9) will select to come from second The pixel of original image 210 ' is used to merge composograph 253 (Fig. 2), and the pixel and its conduct of pixel value 981 Clearly pixel 966 is output to pixel selector 970 to selected saturation degree.In other words, selected saturation degree clearly pixel 966 be pixel that is can checking in the composite image and not being too close to saturation point.Of course, it is possible to by different tests come Set the saturation difference comparator 958.For example, the maximum saturation fallen into instead of selection in the range of bright value range 960 Difference signal, saturation difference comparator 958 can be configured to the minimum saturation degree for selecting to fall into the range of value range 960 Difference signal.If the upper limit of bright value range 960 is set to be sufficiently below saturation value so that it is guaranteed that be not problem close to saturation, Then this test will select most bright acceptable pixel, and the pixel is from the 3rd original image 216 ' in Fig. 9 B examples Pixel.

Darkness difference signal 950,952,954,956 is applied to darkness difference comparator 962.Darkness difference comparator 962 select darkness difference signal that is maximum but still falling within dark value range 964.In other words, it is desirable to select less dark And pixel that is visible in the composite image and still falling within certain span.Clearly pixel 968 connects selected darkness And be applied to pixel selector 970.In Fig. 9 A examples, dark value range 964 can be configured to provide as shown in Figure 9 C Dark scope 964 '.Therefore in this example, the pixel value 980 from the first original image 204 ' is due to less than dark scope 964 ' And be rejected, and the pixel value 983 from the 4th original image 222 ' higher than dark scope 964 ' due to being rejected.From Corresponding second and the 3rd original image 210 ', 216 ' the two pixel values 981,982 between, from the 3rd original image 216 ' The saturation difference signal 954 that has of pixel be more than the saturation difference signal of the pixel from the second original image 216 ' 952.Therefore, according to test explained above, darkness difference comparator 962 (Fig. 9) will select to come from the 3rd original image 210 ' The pixel be used to merge composograph 253 (Fig. 2), and the pixel and its pixel value 982 are clear as the darkness selected Clear pixel 968 is output to pixel selector 970.In other words, clearly pixel 968 is in the composite image to selected darkness Pixel that is can checking and not being too close to dim spot.Of course, it is possible to set the darkness comparison in difference by different tests Device 962.For example, the maximum saturation difference signal fallen into instead of selection in the range of dark value range 964, saturation difference compares Device 962 can be configured to the minimum darkness difference signal for selecting to fall into the range of value range 964.If dark value range 964 Lower limit be set to sufficiently above dark value so that it is guaranteed that the pixel is visible in the composite image, then this test will choose Most dark acceptable pixel is selected, the pixel is the pixel from the second original image 216 ' in Fig. 9 B examples.

Pixel selector 970 for selected preferred pixel 972 selected saturation degree clearly pixel 966 with it is selected Darkness is clearly selected between pixel 968.Depending in saturation difference comparator 958 as explained above and darkness differential The bright value range 960 and dark value range 964 used in different comparator 962, these pixels can be same pixel.Further, If not no clearly pixel 966 of the selected saturation degree from saturation difference comparator 958, pixel selector 970 will Select clearly pixel 968 of the darkness from darkness difference comparator 962.If not from darkness difference comparator 962 Selected darkness clearly pixel 968, then pixel selector 970 will automatically select full from saturation difference comparator 958 With degree clearly pixel 966.Selected pixel 972 is then transferred to image composer 974, the generation synthesis of described image maker Image.If however, not selected saturation degree clearly pixel 966 and without the darkness selected clearly pixel 968, Pixel selector 970 will not transmit selected pixel 972 to image composer 974.If multiple without occurring in composograph Pixel, then can with it is as discussed above by adjust exposure period, exposure across the parameter such as stage of power waveform or By the sensitivity for the operating parameter such as photosensor array for adjusting camera 126, aperture, the optional submerged plate etc. that becomes come in original More acceptable pixels are created in beginning image.Further, it can be allowed to include with adjusting range value 960,964 more selected Pixel.

Pixel selector 970 can apply in multiple indexs any one come in saturation degree clearly pixel 966 and darkness Clearly selected to send selected pixel 972 to image composer 974 between pixel 968.For example, pixel selector 970 can equipped with medium pixel value and can by saturation degree clearly pixel 966 and darkness clearly pixel 968 with it is described Medium pixel value is compared.Pixel selector 970 can select the pixel value having to deviate the farthest pixel of the medium value, Or the pixel value having can be selected to deviate the minimum pixel of the medium value.The former can provide for the composograph of gained Bigger contrast, and the latter can provide bigger homogeneity in the composograph of gained.In some cases, saturation degree is selected Clearly pixel 966 or darkness clearly pixel may without too big difference, therefore random selection or the two pixels it Between alternate selection be probably gratifying.

Fig. 9 image combiner 900 is that one kind of the pixel for obtaining combination image can be selected from original image Exemplary approach.Other modifications can be made.For example, it is convenient to omit darkness comparator 934,936,938,940 and darkness differential Different comparator 962.Bright value range 960 can be adjusted so that do not need darkness comparator.For high speed imaging application, these ratios It can be hardware comparator compared with device, thus image can be provided in nearly real time.In addition, the comparator of image combiner 900 is also Comparison device can be included, the comparison device works as a part for the controller 124 of software implementation.Selected Pixel 972 is then transferred to image composer 974, and described image maker generates composograph so as on display 978 Show and/or to be analyzed in analyzer 976.Analyzer 976 may be implemented within video system controller 124 (Fig. 1), And display 978 can be implemented as the display device 138 in Fig. 1, and composograph 140 is on said display means with static Or video format is shown.

A series of original images of merging are illustrated in Figure 10 to create another example process 1000 of composograph, The process can be conducive to faster display speed and video fluency.In this example process 1000, instead of such as scheming 2nd, shown in 3,4 and 5 example by four (or some other suitable quantity) in batch or groups of original image merges and created The composograph 1031 built in composograph, Figure 10,1032,1033,1034,1035,1036,1037,1038,1039 ..., N It is to merge to form with continuous serial renewal process.Correspondingly, camera 126 (Fig. 1) produce original image 1004 ', 1010 ', 1016 ', 1022 ', 1006 ', 1012 ', 1018 ', 1024 ', 1008 ', 1014 ', 1020 ', 1026 ' ..., n ' is created that afterwards New (renewal) composograph, rather than wait the generation of camera 126 four groups of before next composograph is created Original image.For example, as shown in Figure 10, by by from the one or four original image 1004 ', 1010 ', 1016 ', 1022 ' Potting gum creates the first composograph 1031.Then by using the pixel from the 5th original image 1006 ' and throwing Abandon the pixel of (that is, without using) from the first original image 1004 ', while be continuing with from second, third and it is the 4th original The pixel of image 1010,1016, to create the second composograph 1032.Similarly, when camera 126 generates the 6th original image When 1012 ', using the pixel from the 6th new original image 1012 ', together with from the three, the 4th and the 5th original image 1016 ', 1022 ' and 1006 ' pixel, to create the 3rd composograph 1033.Equally, with the original graph newly produced accordingly As 1012 ', 1018 ', 1024 ', 1008 ', 1014 ', 1020 ', 1026 ' ..., n ', together with original from just preceding three Image, come create each Zhang Suihou composograph 1033,1034,1035,1036,1037,1038,1039 ..., N.

Equally, for convenience and be compared, the power waveform 1002 in Figure 10 be illustrated as sine, similar in Fig. 2 Power waveform 200, but other AC or DC waveforms can be used.And for convenience and be compared, during exposure in Figure 10 Between section 1004,1010,1016,1022,1006,1012,1018,1024,1008,1014,1020,1026 be accordingly with Fig. 2 In the identical of exposure period 204,210,216,222,206,212,218,224,208,214,220,226.Moreover, Figure 10 In these exposure periods have with the exposure in Fig. 2 start trigger point and exposure termination trigger point identical exposure start to touch Hair point and identical exposure termination trigger point, and identical technology can be used to set up these trigger points.Therefore, in order to It is convenient and avoid it is unnecessary mix and repeat, not shown exposure in Fig. 10 starts trigger point and exposure termination trigger point. As long as it is sufficient to refer to herein below：Original image 1004 ' in Figure 10,1010 ', 1016 ', 1022 ', 1006 ', 1012 ', 1018 ', 1024 ', 1008 ', 1014 ', 1020 ', 1026 ' can by with any original image phase in the example of Fig. 2,3,4 and 5 With mode create.

It can use being shown in Fig. 8,9,9A, 9B and 9C and create the first synthesis in consolidation process described above Image 1030.For example shown in fig. 11 in association with Fig. 8, first, second, and third original image 1004 ', 1010 ', 1016 ' respective pixel stream is admitted in corresponding first, second, and third shift register 810,812,814, with Just first, second, and third pixel stream is deferred to be enough it is right in time with the pixel stream of the 4th original image 1022 ' Together, as explained above.As a result, first, second, third and fourth original image 1004 ', 1010 ', 1016 ', 1022 ' All four pixel streams mutually in the same time T1 be output 820,822,824,826 so that this four original images Respective pixel in 1004 ', 1010 ', 1016 ', 1022 ' reach simultaneously image combiner 900 (Fig. 9) corresponding input 902, 904、906、908.Image combiner 900 is then from this four pixel streams of original image 1004 ', 1010 ', 1016 ', 1022 ' Middle selection pixel carrys out the first composograph 1031 (Figure 10) of generation in image composer 974 (Fig. 9), as explained above.

As explained above, when camera 126 (Fig. 1) generates the 5th original image 1006 ' (Figure 10), create in Figure 10 New (second) composograph 1032 be to be come from by using the new pixel data from new original image 1006 ' and abandoning The pixel data of first original image 1004 ' is come the composograph 1031 before updating.Therefore, (second) composograph of renewal 1031 are formed by the potting gum from the second to the 5th original image 1010 ', 1016 ', 1022 ', 1006 '.Referring to Fig. 8 and 9, such sequential serial renewal process can for example by by the pixel stream from just preceding original image after from it Before original image pixel stream after be introduced into the shift register 810,812,814 of delay hardware 800 and complete.Cause This, the pixel stream from newest original image will be right in time with the pixel stream from just preceding three original images Together.In order to show the time property of this example process, illustrated in fig. 11 with symbol sebolic addressing delay hardware 800 and thirdly Individual shift register 810,812,814, but it is actual using only this delay hardware 800.As mentioned above, by that will come from To be come from the pixel stream feeding delay hardware 800 of one or four original image 1004 ', 1010 ', 1016 ', 1022 ' this four The corresponding respective pixel for opening original image is alignd in time, to create the first composograph 1031.From first three original graph As 1004 ', 1010 ', 1016 ', 1022 ' pixel stream is admitted in shift register 810,812,814, so as to by these pixels Stream is deferred in time to be enough to be allowed to align in time to export simultaneously to image combiner 900 (Fig. 9) in moment T1. Meanwhile, when camera 126 (Fig. 1) produces five new original image 1006 ', second, third and the 4th original image 1010 ', 1016 ', 1022 ' pixel stream is admitted in first, second, and third shift register 810,812,814 to be prolonged respectively Time quantum appropriate late so as to align in time with the pixel stream from the 5th new original image 1006 '.Correspondingly, postpone Hardware 800 moment T2 to second, third, the 4th and the 5th original image 1010 ', 1016 ', 1022 ', 1006 ' pixel stream Output 820,822,824,826 will align in time each other.Correspondingly, second, third, the 4th and the 5th original image 1010 ', 1016 ', 1022 ', 1006 ' pixel stream alignd in time is delivered to image combiner 900 (Fig. 9) input 902nd, 904,906,908, to carry out pixel selection and the second composograph 1032 of generation in image composer 974 (Fig. 9) (Figure 10), described above.

In delay hardware 800 by second, third, the 4th and the 5th original image 1010 ', 1016 ', 1022 ', 1006 ' Pixel stream while align in time, when camera 126 (Fig. 1) produces six new original image 1012 ', the 3rd, the The pixel stream of four and the 5th original image 1016 ', 1022 ', 1006 ' is admitted to first, second, and third shift register respectively 810th, in 812,814 so as to postponed appropriate time quantum so as to the pixel stream from the 6th new original image 1012 ' Align in time.Correspondingly, delay hardware 800 moment T3 to the three, the four, the 5th and the 6th original image 1016 ', The output 820,822,824,826 of 1022 ', 1006 ', 1012 ' pixel stream will align in time each other.Correspondingly, the 3rd, The pixel stream alignd in time of four, the 5th and the 6th original image 1016 ', 1022 ', 1006 ', 1012 ' is delivered to The input 902,904,906,908 of image combiner 900 (Fig. 9), to carry out pixel selection and (scheme in image composer 974 9) the 3rd composograph 1033 (Figure 10) of generation in, described above.

By the three, the four, the 5th and the 6th original image 1016 ', 1022 ', 1006 ', 1012 ' in delay hardware 800 Pixel stream while align in time, when camera 126 (Fig. 1) produces seven new original image 1018 ', the 4th, the The pixel stream of five and the 6th original image 1022 ', 1006 ', 1012 ' is admitted to first, second, and third shift register respectively 810th, in 812,814 so as to postponed appropriate time quantum so as to the pixel stream from the 7th new original image 1018 ' Align in time.Correspondingly, delay hardware 800 moment T4 to the four, the five, the 6th and the 7th original image 1022 ', The output 820,822,824,826 of 1006 ', 1012 ', 1018 ' pixel stream will align in time each other.Correspondingly, the 4th, The pixel stream alignd in time of five, the 6th and the 7th original image 1022 ', 1006 ', 1012 ', 1018 ' is delivered to The input 902,904,906,908 of image combiner 900 (Fig. 9), to carry out pixel selection and (scheme in image composer 974 9) the 4th composograph 1034 (Figure 10) of generation in, described above.

The identical sequential serial renewal process ad infinitum continues, until by user or automatically stopping.Figure 11 passes through The pixel stream of 9th original image 1008 ' is alignd with the pixel stream of preceding three original images 1012 ', 1018 ', 1024 ' For creating the 6th composograph 1036, to show the alignment procedure in time.As mentioned above, in Figure 10 examples Merging process in, by camera 126 (Fig. 1) produce original image 1004 ', 1010 ', 1016 ', 1022 ', 1006 ', 1012 ', 1018 ', 1024 ', 1008 ', 1014 ', 1020 ', 1026 ' ..., n ' create new (renewal) composograph afterwards, rather than Camera 126 is waited to produce four groups of original images before next composograph is created.Therefore, if power waveform 1002 frequency is set to exemplary 110Hz, as shown above for Fig. 2-5 examples, then will be come with 110 frame per second Create composograph 1031-1039 ..., N, but each frame includes all images letter across 1/27 second (that is, from four exposures) Breath.Therefore, for the power waveform with the identical frequency, Figure 10 technology time per unit generate be Fig. 2-5 skill Four times of composograph of the image that art is created.

As mentioned above, a variety of different phenomenons occurred during welding process in the welding region 109 (Fig. 1) be with Power supply wave shape and become and can be controlled by power supply wave shape or influence.For example, the shape of the DC electric power waveform 1202 in Figure 12 A The development of drop 121 of the shape with being melted from the distal end of electrode welder 106 is corresponding and will influence the development.Modern welding The source of welding current 122 in power supply, such as Fig. 1, can be programmed to produce the DC electric power waveform with shape desired and characteristic 136.The power waveform 1202 of given shape in Figure 12 A is in moment t₁With t₂Between have be in base current (I) amperage water Flat flat phase 1205, the flat phase provides the electric current of pilot arc 107 and the basic crack of plasma cone 108. The formation of the drop 121 of the electrode metal of fusing starts in this flat foundation phase 1205, such as in welding region 109 Shown in one illustrated example Figure 128 1.Then in moment t₂, start the slow liter stage 1207.Period in stage 1207, welding are risen slow The amperage of electric current is slow to be risen to increase the heat in electrode and accelerate the formation of drop 121.In moment t₃Reach desired peak It is worth after amperage, peak ampere number is maintained in the peak ampere number stage 1209, until moment t₃, now amperage start Reduce in finishing phase 1211.Drop 121 is formed completely in the peak ampere number stage 1209, until separated with electrode 106 Point, as shown in second illustrated example Figure 128 2 in welding region 109.Then, in finishing phase 1211, drop 121 is Through being separated with electrode 106, as shown in the 3rd illustrated example figure in welding region 109.Drop 121 then falls on welding pool In 111, it is fused with the fusing metal in the fusion zone 113 of workpiece 110,112 herein.As welding tip 104 continues to move Move (as shown in the arrow 105 in Fig. 1), molten metal cools down and is solidified into bead 103.Therefore, carried to camera 126 (Fig. 1) Start control signal and exposure termination control signal for exposure to produce and the weight of selected stage in the stage 1205,1209,1211 The exposure period of conjunction enables welding video to create these feature (development ranks of such as drop 121 with control system 100 Section) composograph, as explained below, these images be can check in real time either it is storable so as to after Check or analyze.

Referring now primarily to Figure 12 B, four cycles of the DC electric power waveform 1202 of such as shaping, and camera are illustrated With gradually increased first, second, third and fourth exposure period in each cycles of 126 (Fig. 1) in this four cycles 1204th, 1210,1216,1222 first, second, third and fourth original image 1204 ', 1210 ', 1216 ', 1222 ' is produced.When So, in actual use, much more original image will be produced in much more cycle in power waveform 1202.In Figure 12 B In example, first, the is produced in corresponding first, second, third and fourth exposure period 1204,1210,1216,1222 2nd, the third and fourth original image 1204 ', 1210 ', 1216 ', 1222 ', these exposure periods are in the flat of power waveform 1202 Occur during the smooth basic amperage stage 1205.Therefore in Figure 12 B examples, the first, second, third and fourth time for exposure Section 1204,1210,1216,1222 causes optical sensor or detector in the photosensor array 1285 of camera 126 in drop 121 to be ready exposing the luminous energy for sending or reflecting from welding region 109 when the far-end of electrode welder 106 is initially formed, such as Shown in first illustrated example Figure 128 1 of welding region 109 in Figure 12 A, because the phenomenon is on the basis in power waveform cycle Occur during the amperage stage 1205.And in this example, first, second, third and fourth exposure period 1204, 1210th, 1216,1222 have gradually longer duration, therefore every successive original similar to Fig. 2 examples discussed above Beginning image 1204 ', 1210 ', 1216 ', 1222 ' has been produced since being from the increasing luminous energy of welding region 109.However, Exposure period 1204,1210,1216,1222 can have the mutually the same duration, such as above for the exemplary of Fig. 4 Described by technology.

As discussed on the example before in Fig. 2,3,4,5 and 10, it can use to the threshold value in power waveform Detection start these exposure periods 1204,1210,1216,1222, or alternatively, the source of welding current 122 can be provided The control signal corresponding with such threshold value in the power waveform.Also as explained in the example of Fig. 2,3,4,5,10, Video system controller 124 (Fig. 1) or the alternatively source of welding current 122 can be stood when detecting or such threshold value occur I.e. or from such detect or appearance trigger exposure period 1204,1210,1216,1222 after delay.Example Such as, the beginning threshold value of exposure period 1204,1210,1216,1222 may be at starting current threshold point 1212,1213, 1214th, 1215, now detect the basic amperage water that amperage reaches the basic amperage stage 1205 of power waveform 1202 It is flat, and the actual beginning trigger point 1217,1218,1219,1220 of corresponding exposure period 1204,1210,1216,1222 by regarding Picture system controller 124 (being alternatively soldered power supply 122) delays predetermined amount of time, and these predetermined amount of time are confirmed as using In being provided as specific purpose or the stage desired by effect and exposure period.Will also terminate trigger point 1225,1226, 1227th, 1228 are set as that current threshold point 1212,1213,1214,1215 has accordingly for specific mesh since corresponding Or effect desired by time delay.

As shown in diagram in Figure 12 B, most short exposure period 1204 passes through from welding region 109, for example from electric arc 107 The most bright most strong luminous energy for sending or reflecting with plasma 108 is in the middle body 1287 of photosensor array 1285 Optical sensor or detector provide preferable luminous energy exposure.Therefore, photosensor array 1285 is from the exposure period 1204 The original image 1204 ' of generation has the fine resolution of these features, such as electric arc 107 and plasma 108.Meanwhile, most Short exposure period 1204 does not produce the enough luminous energy of the relatively dark-part from welding region 109 to cause outside remaining The optical sensor or detector that divide in 1288 produce the original image of such feature compared with dark-part of welding region 109.Cause This, from exposure period 1204 produce gained original image 1204 ' illustrate only most bright feature, such as electric arc 107 and from Daughter 108, and the remainder of original image 1204 ' includes dark pixel 1290.

Next, slightly longer exposure period 1210 causes the middle body of the saturation of photosensor array 1285 1286, because the high-strength light for sending or reflecting from most bright feature such as electric arc 107 and plasma 108 can make optical sensor battle array Row 1285, the optical sensor in the middle body 1286 or detector are in the slightly longer exposure period 1210 Middle saturation.Meanwhile, slightly longer exposure period 1210 for the saturation of photosensor array 1285 middle body 1286 weeks Optical sensor or detector in the center section 1287 enclosed provide preferable luminous energy exposure, because from welding region 109 Between feature such as welding pool 111, fusion zone 113 in part and the drop 121 of the development luminous energy that sends or reflect be not enough to In photosensor array 1285, described luminous energy is set to focus on optical sensor or detector saturation thereon.Welding region 109 Dark outer portion does not send or reflected enough luminous energy to pass the light in the outer portion 1288 of photosensor array 1285 Sensor or detector produce any image.Therefore, photosensor array 1285 is from the slightly longer exposure period 1210 The original image 1210 ' of generation has these intermediate light features such as welding pool 111, fusion zone 113 and the liquid in formation The fine resolution of drop 121.Meanwhile, slightly longer exposure period 1210 do not produce from welding region 109 compared with Optical sensor or detector production in remaining outer portion 1288 of the enough luminous energy of dark-part to cause photosensor array 1285 Any original image of such feature compared with dark-part of raw welding region 109.Therefore, from slightly longer exposure period The 1210 gained original images 1210 ' produced illustrate only quite bright but not most bright feature, such as welding pool 111, molten Change area 113 and the drop 121 in formation.The middle body pixel 1291 of original image 1210 ' becomes saturation, and original image 1210 ' remaining outer portion only includes dark pixel 1290.

Next, appropriateness is longer exposure period 1216 causes the even more big saturation of photosensor array 1285 Middle body 1286 because not only from most bright feature such as electric arc 107 and plasma 108 but also from slightly darker The luminous energy that feature such as welding pool 111, fusion zone 113 and the drop 121 in formation send or reflected makes photosensor array Optical sensor in 1285, in the even more big middle body 1286 or detector saturation.Meanwhile, appropriateness is longer Exposure period 1216 is the light in the center section 1287 around the middle body 1286 of the saturation of photosensor array 1285 Sensor or detector provide preferable luminous energy exposure, because from such as electrode of the feature in the center section of welding region 109 106 and workpiece 110,112 is sent or the luminous energy that reflects is in and in photosensor array 1285, described luminous energy is focused on thereon Optical sensor or the detector image pixel that produces these features proper range in.The dark outside of welding region 109 Divide and do not send or reflect enough luminous energy to make the optical sensor in the outer portion 1288 of photosensor array 1285 or detection Device produces any image.Therefore, the original image that photosensor array 1285 is produced from the longer exposure period 1216 of appropriateness 1216 ' have the fine resolution of feature, such as electrode 106 and the workpiece 110,112 of these intermediate lights.Meanwhile, appropriateness is more Long exposure period 1216 does not produce the enough luminous energy of the relatively dark-part from welding region 109 to cause optical sensor Optical sensor or detector in remaining outer portion 1288 of array 1285 produce the such compared with dark-part of welding region 109 Any original image of feature.Therefore, the gained original image 1216 ' produced from the longer exposure period 1216 of appropriateness only shows Medium bright feature, such as welding pool 111, fusion zone 113 and the drop 121 in formation are gone out.In original image 1216 ' Partial pixel 1291 is entreated to become saturation, and remaining outer portion of original image 1216 ' only includes dark pixel 1290.

Next most long exposure period 1222 is caused in the even more big saturation of photosensor array 1285 Entreat part 1286 because from it is all be not most dark feature, for example from electric arc 107 and plasma 108, welding pool 111, molten Change area 113, the drop 121 in formation, the inside of electrode 106 and workpiece 110,112 distributes or the luminous energy of reflection passes light Optical sensor in sensor array 1285, in the even more big middle body 1286 or detector saturation.Meanwhile, most Long exposure period 1222 is the light in the outer portion 1287 around the middle body 1286 of the saturation of photosensor array 1285 Sensor or detector provide preferable luminous energy exposure, because for example being welded from the feature in the outer portion 1287 of welding region 109 Connect that the outer portion of nozzle 104 and workpiece 110,112 is sent or the luminous energy reflected is in and makes in photosensor array 1285, institute Luminous energy is stated to focus in the proper range for the image pixel that optical sensor or detector thereon produce these features.Cool down and consolidate The bead 103 (invisible in Figure 12 B) of change will also be shown in original image 1222 ', be included if the camera is in If the appropriate visual angle of the bead 103.Therefore, photosensor array 1285 from most long exposure period 1222 produce it is original Image 1222 ' has the outer portion and bead 103 of these intermediate light features such as soldering machine nozzle 104, workpiece 110,112 Fine resolution.Therefore, the gained original image 1222 ' produced from most long exposure period 1222 illustrate only dark spy Levy, for example the outer portion and bead 103 of welding tip 104, workpiece 110,112.The middle body picture of original image 1222 ' Element 1291 is saturation.

The original image that camera 126 is produced during corresponding exposure period 1204,1210,1216,1222 by camera 126 1204 ', 1210 ', 1216 ', 1222 ' (every available pixel with some in welding region 109 but not all feature) quilts It is merged together to create composograph 1240.As shown in Figure 12 B and as discussed above, composograph 1240 has display The pixel of all features in welding region 109, wherein drop 121 start to be formed in the far-end of electrode 106, because described existing As occurring as illustrated in fig. 12 and in the basic amperage stage 1205 of the power waveform 1202 as discussed above, and expose The light period 1204,1210,1216,1222 is located at the stage.It can use discussed above any for producing synthesis The process of image to produce composograph 1240 from original image 1204 ', 1210 ', 1216 ', 1222 '.

When the exemplary exposure period 1224,1230,1236,1242 in Figure 12 C is shown as with exposure in Figure 12 B Between section 1204,1210,1216,1222 it is identical, except the exposure period 1224,1230,1236,1242 in Figure 12 C is displaced to The peak ampere number stage 1209 of power waveform 1202, the molten metal drop 121 now formed in the distal end of electrode 106 is complete Develop and separated with electrode 106, it is as illustrated in fig. 12 and above-described.In Figure 12 C examples, exposure period 1224, 1230th, 1236,1242 can be by detecting or being otherwise indicated that the levels of current of increase reaches peak ampere number rank The threshold current level of section 1209 starts.Correspondingly, the beginning current threshold of exposure period 1224,1230,1236,1242 Starting point of the point 1231,1232,1233,1234 in the peak ampere number stage 1209, but the exposure period 1224 of reality, 1230th, 1236,1242 be since start current threshold point 1231,1232,1233,1234 by time delay the trigger point to 1244、1245、1246、1247.Trigger point 1251,1252,1253,1254 will also be terminated and be set as the current threshold since corresponding Value point 1231,1232,1233,1234 has the time delay desired by specific purpose or effect accordingly.

As shown in diagram in Figure 12 C, most short exposure period 1224 passes through from welding region 109, for example from electric arc 107th, the most bright most strong luminous energy that plasma 108 and drop 121 send or reflected is in the center of photosensor array 1285 Optical sensor or detector in part 1287 provide preferable luminous energy exposure.Therefore, photosensor array 1285 exposes from described The original image 1224 ' that the light period 1224 produces has these features, such as electric arc 107, plasma 108 and drop 121 Fine resolution.Meanwhile, most short exposure period 1224 does not produce the foot of the relatively dark-part from welding region 109 Luminous energy is reached to cause optical sensor or detector in remaining outer portion 1288 to produce the such compared with dark-part of welding region 109 Feature original image.Therefore, the gained original image 1224 ' produced from exposure period 1224 illustrate only most bright spy Levy, for example electric arc 107, plasma 108 and drop 121, and the remainder of original image 1224 ' includes dark pixel 1290。

Next, slightly longer exposure period 1230 causes the middle body of the saturation of photosensor array 1285 1286, because light can be made from the most bright feature high-strength light that for example electric arc 107, plasma 108 and drop 121 send or reflected Sensor array 1285, the optical sensor in the middle body 1286 or detector are in the slightly longer exposure Between saturation in section 1230.Meanwhile, slightly longer exposure period 1230 is the central portion of the saturation of photosensor array 1285 Optical sensor in center section 1287 or detector around points 1286 provide preferable luminous energy exposure, because from welding region The luminous energy that feature such as welding pool 111 and fusion zone 113 in 109 center section send or reflected is insufficient to allow light sensing In device array 1285, described luminous energy focuses on optical sensor or detector saturation thereon.Welding region 109 it is dark outer Part does not send or reflects enough luminous energy to make the optical sensor in the outer portion 1288 of photosensor array 1285 or inspection Survey device and produce any image in the slightly longer exposure period 1230.Therefore, photosensor array 1285 is from described The original image 1230 ' that slightly longer exposure period 1230 is produced has these intermediate light feature such as welding pools 111 and the fine resolution of fusion zone 113.Meanwhile, slightly longer exposure period 1230 is not produced from weld zone Optical sensor in remaining outer portion 1288 of the enough luminous energy of the relatively dark-part in domain 109 to cause photosensor array 1285 or Detector produces any original image of such feature compared with dark-part of welding region 109.Therefore, from slightly longer exposure The gained original image 1230 ' that the light period 1230 produces illustrate only quite bright but not most bright feature, for example, weld molten Pond 111 and fusion zone 113.The middle body pixel 1291 of original image 1230 ' becomes saturation, and original image 1230 ' its Besides part only includes dark pixel 1290.

Next, appropriateness is longer exposure period 1236 causes the even more big saturation of photosensor array 1285 Middle body 1286 because not only from most bright feature such as electric arc 107, plasma 108 and drop 121 but also being omitted Micro- darker feature such as welding pool 111 and fusion zone 113 are sent or the luminous energy that reflects make it is in photosensor array 1285, Optical sensor or detector saturation in the even more big middle body 1286.Meanwhile, the appropriateness longer time for exposure Section 1236 for photosensor array 1285 saturation middle body 1286 around center section 1287 in optical sensor or Detector provides preferable luminous energy exposure, because from the feature in the center section of welding region 109 such as electrode 106 and workpiece 110th, 112 luminous energy for sending or reflecting are in the light sensing for making in photosensor array 1285, described luminous energy focus on thereon Device or detector are produced in the proper range of the image pixel of these features.The dark outer portion of welding region 109 is not sent out Go out or reflect enough luminous energy and appoint produce optical sensor or detector in the outer portion 1288 of photosensor array 1285 What image.Therefore, the original image 1236 ' that photosensor array 1285 is produced from the longer exposure period 1236 of appropriateness has The fine resolution of the features of these intermediate lights, such as electrode 106 and workpiece 110,112.Meanwhile, moderately during longer exposure Between section 1236 the enough luminous energy of the relatively dark-part from welding region 109 is not produced to cause photosensor array 1285 Optical sensor or detector in remaining outer portion 1288 produce any of such feature compared with dark-part of welding region 109 Original image.Therefore, the gained original image 1236 ' produced from the longer exposure period 1236 of appropriateness illustrate only medium bright Feature, such as welding pool 111 and fusion zone 113.The middle body pixel 1291 of original image 1236 ' becomes saturation, and Remaining outer portion of original image 1236 ' only includes dark pixel 1290.

Next most long exposure period 1242 is caused in the even more big saturation of photosensor array 1285 Entreat part 1286 because from it is all be not most dark feature, for example from electric arc 107, plasma 108, drop 121, welding it is molten Pond 111, fusion zone 113, the inside of electrode 106 and workpiece 110,112 distributes or the luminous energy of reflection makes photosensor array Optical sensor in 1285, in the even more big middle body 1286 or detector saturation.Meanwhile, during most long exposure Between section 1242 for photosensor array 1285 saturation middle body 1286 around outer portion 1287 in optical sensor or Detector provides the exposure of preferable luminous energy, because from the feature such as welding tip in the outer portion 1287 of welding region 109 104 and the outer portion of workpiece 110,112 send or the luminous energy that reflects is in and makes luminous energy in photosensor array 1285, described In the proper range for focusing on the image pixel that optical sensor or detector thereon produce these features.The weldering for cooling down and solidifying Pearl 103 (invisible in fig. 12 c) will also show in original image 1242 ', if the camera, which is in, includes the weldering If the appropriate visual angle of pearl 103.Therefore, the original image that photosensor array 1285 is produced from most long exposure period 1242 1242 ' have the good of these intermediate light features such as soldering machine nozzle 104, the outer portion of workpiece 110,112 and bead 103 Good resolution ratio.Therefore, the gained original image 1242 ' produced from most long exposure period 1242 illustrate only dark feature, Such as outer portion and bead 103 of welding tip 104, workpiece 110,112.The middle body pixel of original image 1242 ' 1291 be saturation.

The original image produced during corresponding exposure period 1224,1230,1236,1242 by camera 126 1224 ', 1230 ', 1236 ', 1242 ' are merged together to create composograph 1240.Composograph 1260 show with The molten metal drop 121 formed completely in the far-end of electrode 106 during the critical point that electrode 106 is separated, because the phenomenon Occur shown in Figure 12 A and as explained above in the peak ampere number stage 1209 of the power waveform 1202, and when exposing Between section 1224,1230,1236,1242 be located at the stage.It can use discussed above any for producing composograph Process come from original image 1224 ', 1230 ', 1236 ', 1242 ' produce composograph 1260.

Exemplary exposure period 1244,1250,1256,1262 in Figure 12 D is shown as and power waveform 1202 Finishing phase 1211 overlap, the molten metal drop 121 from electrode welder 106 is separated with electrode 106 during this period And falling on molten bath 111, as explained above.As shown in diagram in Figure 12 D, most short exposure period 1244 passes through The most bright most strong luminous energy for from welding region 109, for example sending or reflecting from electric arc 107, plasma 108 and drop 121 is Optical sensor or detector in the middle body 1287 of photosensor array 1285 provide preferable luminous energy exposure.Therefore, The original image 1244 ' that photosensor array 1285 is produced from the exposure period 1244 has these feature, such as electric arcs 107th, the fine resolution of plasma 108 and drop 121.Meanwhile, most short exposure period 1244, which is not produced, to be come from The enough luminous energy of the relatively dark-part of welding region 109 welds to cause optical sensor or detector in remaining outer portion 1288 to produce Connect the original image of such feature compared with dark-part in region 109.Therefore, the gained from the generation of exposure period 1244 is original Image 1244 ' illustrate only most bright feature, such as electric arc 107, plasma 108 and drop 121, and original image 1244 ' Remainder include dark pixel 1290.

Next, slightly longer exposure period 1250 causes the middle body of the saturation of photosensor array 1285 1286, because light can be made from the most bright feature high-strength light that for example electric arc 107, plasma 108 and drop 121 send or reflected Sensor array 1285, the optical sensor in the middle body 1286 or detector are in the slightly longer exposure Between saturation in section 1250.Meanwhile, slightly longer exposure period 1250 is the central portion of the saturation of photosensor array 1285 Optical sensor in center section 1287 or detector around points 1286 provide preferable luminous energy exposure, because from welding region The luminous energy that feature such as welding pool 111 and fusion zone 113 in 109 center section send or reflected is insufficient to allow light sensing In device array 1285, described luminous energy focuses on optical sensor or detector saturation thereon.Welding region 109 it is dark outer Part does not send or reflects enough luminous energy to make the optical sensor in the outer portion 1288 of photosensor array 1285 or inspection Survey device and produce any image in the slightly longer exposure period 1250.Therefore, photosensor array 1285 is from described The original image 1250 ' that slightly longer exposure period 1250 is produced has these intermediate light feature such as welding pools 111 and the fine resolution of fusion zone 113.Meanwhile, slightly longer exposure period 1250 is not produced from weld zone Optical sensor in remaining outer portion 1288 of the enough luminous energy of the relatively dark-part in domain 109 to cause photosensor array 1285 or Detector produces any original image of such feature compared with dark-part of welding region 109.Therefore, from slightly longer exposure The gained original image 1250 ' that the light period 1250 produces illustrate only quite bright but not most bright feature, for example, weld molten Pond 111 and fusion zone 113.The middle body pixel 1291 of original image 1250 ' becomes saturation, and original image 1250 ' its Besides part only includes dark pixel 1290.

Next, appropriateness is longer exposure period 1256 causes the even more big saturation of photosensor array 1285 Middle body 1286 because not only from most bright feature such as electric arc 107, plasma 108 and drop 121 but also being omitted Micro- darker feature such as welding pool 111 and fusion zone 113 are sent or the luminous energy that reflects make it is in photosensor array 1285, Optical sensor or detector saturation in the even more big middle body 1286.Meanwhile, the appropriateness longer time for exposure Section 1256 for photosensor array 1285 saturation middle body 1286 around center section 1287 in optical sensor or Detector provides preferable luminous energy exposure, because from the feature in the center section of welding region 109 such as electrode 106 and workpiece 110th, 112 luminous energy for sending or reflecting are in the light sensing for making in photosensor array 1285, described luminous energy focus on thereon Device or detector are produced in the proper range of the image pixel of these features.The dark outer portion of welding region 109 is not sent out Go out or reflect enough luminous energy and appoint produce optical sensor or detector in the outer portion 1288 of photosensor array 1285 What image.Therefore, the original image 1256 ' that photosensor array 1285 is produced from the longer exposure period 1256 of appropriateness has The fine resolution of the features of these intermediate lights, such as electrode 106 and workpiece 110,112.Meanwhile, moderately during longer exposure Between section 1256 the enough luminous energy of the relatively dark-part from welding region 109 is not produced to cause photosensor array 1285 Optical sensor or detector in remaining outer portion 1288 produce any of such feature compared with dark-part of welding region 109 Original image.Therefore, the gained original image 1256 ' produced from the longer exposure period 1236 of appropriateness illustrate only medium bright Feature, such as welding pool 111 and fusion zone 113.The middle body pixel 1291 of original image 1236 ' becomes saturation, and Remaining outer portion of original image 1236 ' only includes dark pixel 1290.

Next most long exposure period 1262 is caused in the even more big saturation of photosensor array 1285 Entreat part 1286 because from it is all be not most dark feature, for example from electric arc 107, plasma 108, drop 121, welding it is molten Pond 111, fusion zone 113, the inside of electrode 106 and workpiece 110,112 distributes or the luminous energy of reflection makes photosensor array Optical sensor in 1285, in the even more big middle body 1286 or detector saturation.Meanwhile, during most long exposure Between section 1262 for photosensor array 1285 saturation middle body 1286 around outer portion 1287 in optical sensor or Detector provides the exposure of preferable luminous energy, because from the feature such as welding tip in the outer portion 1287 of welding region 109 104 and the outer portion of workpiece 110,112 send or the luminous energy that reflects is in and makes luminous energy in photosensor array 1285, described In the proper range for focusing on the image pixel that optical sensor or detector thereon produce these features.The weldering for cooling down and solidifying Pearl 103 (invisible in fig. 12d) will also show in original image 1262 ', if the camera, which is in, includes the weldering If the appropriate visual angle of pearl 103.Therefore, the original image that photosensor array 1285 is produced from most long exposure period 1262 1262 ' have the good of these intermediate light features such as soldering machine nozzle 104, the outer portion of workpiece 110,112 and bead 103 Good resolution ratio.Therefore, the gained original image 1262 ' produced from most long exposure period 1262 illustrate only dark feature, Such as outer portion and bead 103 of welding tip 104, workpiece 110,112.The middle body pixel of original image 1262 ' 1291 be saturation.

For start current threshold point 1263,1264,1265,1266, for exposure period 1244,1250,1256, 1262 can use predetermined amperage in the finishing phase 1211 for detecting power waveform 1202, passage time delay to go to Start trigger point 1267,1268,1269,1270.For example, start current threshold point 1263,1264,1265,1266 can be with There is the place of detectable amperage decline, passage time delay and go to desired exposure and open in the peak ampere number stage 1209 Beginning trigger point 1267,1268,1269,1270.Alternatively, can be by specifically starting current threshold is set in power waveform 1202 Finishing phase 1211 on ad-hoc location, here exposure period 1244,1250,1256,1262 will start, in this situation Lower trigger point 1267,1268,1269,1270 will start current threshold point.Will also terminate trigger point 1271,1272,1273, 1274 are set as that current threshold point 1231,1232,1233,1234 has corresponding time delay since corresponding, such as in order to Desired by specific purpose or effect, or they can be set as to the termination current threshold water that specifically can detect It is flat.The original image 1244 ' that is produced during corresponding exposure period 1244,1250,1256,1262,1250 ', 1256 ', 1262 ' are merged together to create composograph 1280 by camera 126.Composograph 1280 is shown and electrode 106 The molten metal drop 121 that distal end separates and dropped towards welding pool 111, because the phenomenon is in the receipts of power waveform 1202 Occur in the tail stage 1211, exposure period 1244,1250,1256,1262 is located at the stage.It can use discussed above Any process for being used to produce composograph to produce composograph from original image 1244 ', 1250 ', 1256 ', 1262 ' 1280., can be by the way that exposure period be positioned at into power waveform 1202 as the example in Figure 12 B, 12C and 12D is shown Different phase, to catch and show the different characteristic in welding region 109.In composograph 1240 (Figure 12 B), drop 121 It is shown as to be ready starting being formed in the far-end of electrode welder 106, and composograph 1260 (Figure 12 C) shows complete formation And the drop 121 at the critical point separated with electrode 106, and composograph 1280 shows and separated with electrode 106 And turn welding pool 111 be in midway drop 121.By by time for exposure field offset come the difference with power waveform Stage aligns, and can use these in the seizure welding process of camera 126 and many other different phenomenons.When in welding operation During from the moment of power waveform 1202 exposure period produce a series of composographs when, such as with quick Sequence can in real time be looked into as the successive frame (for example, 24 to 30 composographs per second) in video in the display device See the phenomenon occurred in the moment.In other words, the composograph shown in display device 138 can look like one Image is opened, but it is actually the continuous composograph sequence shown with rapid serial (for example, 24 to 30 images per second), Human eye and human brain are regarded as an image.The different phase that exposure period is offset into power waveform 1202 can to use Family can check other features and phenomenon of welding process in real time.Such stage offset to exposure period can be increased Amount formula, or they can carry out by continuously sweeping these power waveforms stage.For example, whole in power waveform 1202 All stages in the individual cycle are upper, i.e. from flat foundation phase 1205 through too slow liter of stage 1207, across peak ampere number rank Section 1209, drop to along finishing phase 1211 in flat basic amperage stage 1205, Figure 12 D in exposure period 1244th, 1250,1256,1262 slow dynamic skew can occur in drop 121 that the far-end of electrode 106 initially forms, And continue to develop into the video for the drop 121 for separating and falling on electrode 106 on molten bath 111.On the other hand, can even it exist Check during the composograph as video and exposure period 1244,1250,1256,1262 is adjusted in finishing phase 1211 Static position, this results in the composograph of the drop 121 when showing just to leave welding pool 111.Then, these exposures are fixed The position of light period 1244,1250,1256,1262 can enable welder, for example to perform the people welded manually bright The real-time video that he or she welds when holding the tip of welding machine and electrode really is seen, wherein the video shows drop 121 encounter molten bath 111.

Therefore The embodiment provides for checking that welding process and generation have high video dynamic range Combination image system and method.These technologies can be used in automatic welding system, such as automated shown in Fig. 1 Weld in video and control system 100, and in manual system, such as shown in Figure 13 and the manual welding that is described below In video system 1300.The high video dynamic range of the system allow to check in welding process the different piece of weld seam, And background.These composographs thus provide the bulk information on weld seam quality, and this allows adjusting parameter to realize height Quality weld seam.

As mentioned above, the optional dynamic shown in Fig. 1 becomes submerged plate 130 and can be used for further controlling from weld zone It is that electric arc 107, plasma 108, welding drop 121, welding pool 111 and other features in domain 109 are sent, incident Luminous intensity in the light detector elements of camera 126.Optional dynamic becomes submerged plate 130 can be by video system controller 124 Control the luminous energy for sending or reflecting from the feature in welding region 109 or welding region 109 to decay.So, optional dynamic Becoming submerged plate 130 further controls the exposure of camera 126 to be conducive to the aperture of camera 126 and the light detector elements of camera 126 Sensitivity or can be used alone, without adjust camera 126 aperture size or light detector elements sensitivity.Enter One step, optional dynamic, which becomes submerged plate 130, to be operated with the following methods, i.e. so that it is during the initial flash of light of electric arc 107 Only it is activated the short time, the initial flash of light occurs at the peak value of power pulse and when continuing short after the peak value Between.Exemplary dynamic in the exemplary weld and video control system 100 becomes submerged plate 130 can be for example with polymer point Dispersion liquid crystalline substance (PDLC) membrane material manufacture, these materials are commercially available and apply alive change with quickly response The variable light transmittance of change.The dimmed optical filter of the liquid crystal function of submerged plate 130 (can also provide become) for camera be it is commercially available, Such as SwedenLC-Tech Displays AB.In this way, controller 124 can be by applying control voltage Signal come easily control it is described dynamic become submerged plate 130.For example, the power waveform from the source of welding current 122 can will be used as The dimmed plate control signal that negative is produced applies to plate 130, to adjust the light into camera 126 so as to produce uniform light intensity Degree.Other changes of dimmed plate control signal are possible.Video system controller 124 be programmed to be used for will be to camera 126 Beginning and terminate the original image of Trig control signal and dimmed plate control signal and camera 126 and export and synchronize.Replace The exposure period of every original image, can be directed to some or all of original images for being used to create composograph and protect by Dai Di Hold constant, at the same by become submerged plate 130 light transmittance or camera 126 in photosensor array luminous sensitivity or the group of the two Conjunction gradually increases or reduced for continuous original image, to increase at least one or more the original in these original images The possibility of all features in welding region 109 is effectively captured in beginning image.User interface 128 is additionally coupled to video system On controller 124, therefore exhibition in transmissivity and Fig. 1 of the user interface 128 to change the dynamic change submerged plate 130 can be used Welding/the video shown and other operating parameters of control system 100.Optional camera 127 may be fitted with dynamic and become submerged plate 131 and according to being used above for the same way described by camera 126.

Fig. 1 also illustrates optional fluorescence detector 132.Optional fluorescence detector 132 can be used for detecting each weldering The initial flash of light of pulse is connect, to start process shown in Fig. 2-5.Optional fluorescence detector 132 is attached to video system control Video system controller 124 is told to have been detected by weld pulse at the moment to signal on device 124 processed.Then can be with The accurate timing to these exposures is triggered alternately through the signal generated by fluorescence detector 132.Optional optical detection Device 132 can also create trigger event in imaging process controller 124.

The example of welding video system 1300 manually is diagrammatically illustrated in fig. 13, and the manual welding video system can With equipped with above-described some or all of features and ability, including but not limited to Fig. 1 feature and ability.Illustrate welder 1318 adorn oneself with the helmet 1302, have display 1304 on the inner side of the helmet 1302.Display 1304 is such as above in Fig. 1 Camera 126,127 and the described ground of video system controller 124 grasped in response to camera 1306 and electronic equipment bag 1308 Make.Welder 1318 produces bead 1312 using manual arc welder 1310 in the intersection of workpiece 1314,1316.Manual electric arc Welding machine 1310 is controlled by welder 1318, and the welder observes the welding in welding region 1209 in real time on display 1304 Journey.The two cameras 1306 (can optionally be provided with the change submerged plate 130,131 become in submerged plate, such as Fig. 1) are from camera 1306 The two different visual angles generate the original image of welding region 1209 or the feature in welding region 1209 simultaneously, for wound Build two composographs to check to carry out solid, but it is also possible to carry out monocular instrumnent using only one camera and check.From the two The original image of camera 1306 is handled by electronic equipment bag 1308 as explained above, to create two phases from the two visual angles The composograph answered, and this two composographs are simultaneously displayed on display 1304, for example, one from a visual angle Composograph is used to showing the eyes given people, and the second composograph from the second visual angle is used to showing give people another One eye, this creates or enhanced the illusion of 3D depth.Certainly, monoscope display is by this opening and closing from a camera Eyes are presented into image.These composographs are either three-dimensional or monoscopic, all allow welder 1318 performing welding Feature (for example, electric arc, plasma etc.) in welding region, sending or reflect high-strength light energy is checked during program in real time And send or the feature (for example, molten melt drop and molten bath) of the less feature of reflecting brightness and slightly darker feature (example Such as, bead, in workpiece by solder joint etc.).In this way, welder 1318 can in welding process real time inspection environment With background and check plasma, the drop from manual arc welder 1310, molten bath and the weld seam 1312 in development Other piths or feature.In this way, the glass window of the unnecessary portion of the helmet 1302 transmission, because the letter of welder 1318 The display 1304 singly checked on the inner side of the helmet 1302 and whole process can be seen with high video dynamic range, this is to make It is impossible during with typical welders' helmet to be seen through only dimmed glass.

The purpose for displaying and explanation presents the described above of the present invention.This be not intended in detail or Person limits the invention to disclosed exact form, and in view of above teachings, other modifications and variations can be It is possible.It is in order to most preferably explain the principle and its practical application of the present invention, so that thus to select and describe the embodiment The not be the same as Example and different modifications for others skilled in the art to be suitable for considered particular use are come most The present invention is utilized goodly.Word " including (the comprise/comprises/comprising/ used in this manual Include/including/includes) ", including feature, it is intended to indicate in the presence of described feature, integer, part or step Suddenly, but they be not precluded from other one or more features, integer, part, step or its combination presence or addition.Institute's purport Appended claims are being construed to include other alternate embodiments of the present invention, unless limited by prior art.

Claims

1. be claimed its exclusive property or privilege invention and some embodiments be defined it is as follows：

Welding video and control system (100) of the one kind for arc welding system (102), wherein the arc welding system By from the source of welding current (122) periodicity power waveform (136,202,302,402,502,1002,1202) power so as to Bead is produced in welding region (109) on workpiece (110,112), the welding video includes with control system：

Camera (126), the camera have focus on the welding region or in the welding region feature (103,104, 106,107,108,110,111,112,113) photosensor array on, the camera starts control signal in response to exposure to be come So that the photosensor array is to the luminous energy that sends or reflect from the welding region or from the feature in the welding region The feature in welding region that expose to produce the welding region or described a series of original images (204 ', 304 ', 404 ', 504 ', 1004 ', 1224 ')；And

Video system controller (124), the video system controller at the predetermined trigger point on periodicity power waveform to The camera generation exposure starts control signal.

2. it is electric in welding video and control system, including the sensing periodicity power waveform as claimed in claim 1 The electrical characteristic sensor (123) of characteristic (V, I), and wherein, the video system controller senses the periodicity electric power Exposure in waveform starts threshold value (228,238,428,528,1231) and generates the exposure to the camera as response Start control signal.

3. welding as claimed in claim 1 and control system, wherein, on the source of welding current and the periodicity power waveform Predetermined trigger point be generated synchronously it is described exposure start control signal.

4. video and control system are welded as claimed in claim 2, wherein, the camera is in the periodicity power waveform Some stage causes the photosensor array to being sent from the welding region or from the feature in the welding region or instead The luminous energy penetrated exposes one section of exposure period (204,304,404,504,1224).

5. welding video and control system as claimed in claim 4, wherein, the video system controller sense it is described The electrical characteristic (V, I) in periodicity power waveform starts with the predetermined time to prolong after threshold value matches with the exposure It is belated to start control signal to the camera generation exposure.

6. video and control system are welded as claimed in claim 2, wherein, the camera is in response to exposure termination control signal To terminate exposure period, the photosensor array is to from the welding region or from institute during these exposure periods State the luminous energy exposure that the feature in welding region sends or reflected.

7. welding video and control system as claimed in claim 6, wherein, the video system controller sense it is described The electrical characteristic in periodicity power waveform starts with predetermined time delay to come after threshold value matches with the exposure The exposure termination control signal is generated to the camera.

8. video and control system are welded as claimed in claim 6, wherein, the video system controller senses the cycle Property power waveform in the electrical characteristic when match with exposure termination threshold value and generated as response to the camera The exposure termination control signal.

9. video and control system are welded as claimed in claim 2, wherein, the photosensor array includes independent light and passed Sensor, each of these independent optical sensors are during exposure period (204,304,404,504,1004,1224) To being exposed from the welding region or from the discrete portions in the luminous energy that the feature in the welding region is sent and is reflected Light, and wherein, the camera causes the photosensor array to from the weldering in a series of exposure period Region or the luminous energy for sending or reflecting from the feature in welding region exposure are connect, to produce institute with pel array form Each corresponding original image in serial original image is stated, it is every in pel array form described in each corresponding original image Individual pixel has a pixel value, and the pixel value indicates quilt during a corresponding exposure period in these exposure periods The luminous energy that one of optical sensor in the photosensor array absorbs.

10. video and control system are welded as claimed in claim 9, wherein, the video system controller is by being patrolled Volume computing by more than first original image in these original images be merged into the first composograph (253,397,476,576, 1031,1240), the logical operation selects have non-saturated pixel value (942,944,946) from the multiple original image With the pixels of non-dark pixel values (952,954,956) and by selected potting gum into first composograph.

11. video and control system are welded as claimed in claim 10, wherein, the video system controller is by being patrolled Collect computing and second in these original images and follow-up multiple original images are merged into second and follow-up synthesis Image (255,398N, 478,578,1032,1260), the logical operation is from described second and follow-up multiple original images Middle pixel of the selection with non-saturated pixel value and non-dark pixel values and by selected potting gum to described second and after In continuous composograph.

12. welding video and control system as claimed in claim 11, wherein, the video system controller is by described the First, second and follow-up composograph in series crossfire to display device (138) for entering on said display means Row video is shown.

13. welding video and control system, including user interface (128) as claimed in claim 12, the user interface connect It is connected on the video system controller to input video control parameter to the video system controller.

14. video and control system are welded as claimed in claim 13, wherein, the video system controller is programmed to use The periodicity power waveform of the exposure period occurs for change in receiving the input from the user interface Stage, and as response change it is described exposure start threshold value or change in the periodicity power waveform is detected The backward camera generation exposure of exposure beginning threshold value starts control signal or the time of exposure termination control signal prolongs Late.

15. video and control system are welded as claimed in claim 11, wherein, the video system controller carries out logic fortune Calculate described second and follow-up composograph application model to be recognized or analyzed one in for confirmation and welding region The deviation of the parameter preset of individual or multiple features and in response to confirm the deviation and to the source of welding current export one or Multiple signals in the way of correcting the deviation to change the parameter of the periodicity power waveform.

16. video and control system are welded as claimed in claim 11, wherein, the video system controller carries out logic fortune Calculate described second and follow-up composograph application model to be recognized or analyzed one in for confirmation and welding region The deviation of the parameter preset of individual or multiple features and export one to robot system controller in response to confirming the deviation Individual or multiple signals in the way of correcting the deviation to change the physical parameter of the electric arc welder system (102).

17. video and control system are welded as claimed in claim 11, wherein, the video system controller carries out logic fortune Calculate described second and follow-up composograph application model to be recognized or analyzed one in for confirmation and welding region The deviation of the parameter preset of individual or multiple features and in response to confirm the deviation and to the display device or alarm with The output of notice system confirms one or more signals of the deviation.

18. video and control system are welded as claimed in claim 2, wherein, the camera includes dimmed plate (130), described Become submerged plate in response to transmissivity control signal to dynamically adjust light transmission.

19. welding video and control system as claimed in claim 18, wherein, the video system controller is to the camera Become submerged plate and generate the transmissivity control signal.

20. video and control system are welded as claimed in claim 19, wherein, the video system controller generation is used as institute State the transmissivity control signal of the negative of periodicity power waveform.

21. video and control system are welded as claimed in claim 2, wherein, the photosensor array has for luminous energy Adjustable sensitivity, the adjustable sensitivity is can be controlled by the sensitivity control signal of video system controller generation System.

22. welding video and control system as claimed in claim 2, wherein, the camera has an adjustable aperture, it is described can The aperture of tune is can be controlled by the aperture control signal of video system controller generation.

23. one kind is used to create in the welding process powered by periodicity power waveform (136,202,302,402,502,1202) Build welding region (109) or the welding region in feature (103,104,106,107,108,110,111,112,113) A series of original images (204 ', 304 ', 404 ', 504 ', 1004,1224 ') method, in the periodicity power waveform Electrical characteristic (V, I) periodically changes, and methods described includes：

Camera (126) is focused in the feature on the welding region or in the welding region；And

The camera, which is triggered, in the predefined phase of the periodicity power waveform causes the magazine photosensor array pair The luminous energy for sending or reflecting from the feature in the welding region or the welding region exposes a series of time for exposure Section (204,304,404,504,1004,1224), so as to the spy in welding region that create the welding region or described The original image levied.

24. method as claimed in claim 23, including：It is described electric in the periodicity power waveform in response to detecting The predetermined exposure of characteristic starts threshold value, triggers the camera and causes the magazine photosensor array to from the weld zone The luminous energy that the feature in domain or the welding region sends or reflected exposes the serial exposure period, to create Build the welding region or the feature in the welding region these predetermined ranks in the periodicity power waveform The original image of section.

25. method as claimed in claim 23, including：The electrical characteristic in the periodicity power waveform is detected Exposure start threshold value after, the camera is triggered with predetermined time delay so that the magazine photosensor array Luminous energy exposure to sending or reflecting from the feature in the welding region or the welding region.

26. method as claimed in claim 23, including：Difference is provided for some exposure periods in these exposure periods Beginning threshold value, to start in the different phase of the periodicity weld power waveform so that the magazine light is passed Sensor array exposes to the luminous energy for sending or reflecting from the feature in the welding region or the welding region.

27. method as claimed in claim 23, including：There is provided and this for some exposure periods in these exposure periods Other exposure periods in a little exposure periods different duration, so as to the difference for the periodicity power waveform Stage causes the photosensor array to sending or reflecting from the feature in the welding region or the welding region Luminous energy exposure.

28. method as claimed in claim 23, including：The electrical characteristic in the periodicity power waveform is detected Exposure start threshold value after, the camera is triggered with predetermined time delay to terminate these image exposuring times section.

29. method as claimed in claim 23, including：In response to detecting the week for corresponding image exposuring time section The predetermined exposure of the electrical characteristic in phase property power waveform terminates threshold value, triggers the camera to terminate these image exposures Period.

30. one kind is used to create in the welding process powered by periodicity power waveform (136,202,302,402,502,1202) Build welding region (109) or the welding region in feature (103,104,106,107,108,110,111,112,113) Original image (204 ', 304 ', 404 ', 504 ', 1224 ') method, in the periodicity power waveform electrical characteristic (V, I) periodically change, methods described includes：

Camera (126) is focused in the feature on the welding region or in the welding region, wherein the camera In response to exposure start control signal come start cause the magazine photosensor array persistently exposure period (204, 304,404,504,1004,1224) to sending or reflecting from the feature in the welding region or the welding region Luminous energy exposure, so as to the original image of the feature in welding region that create the welding region or described；

Detect the electrical characteristic in the periodicity power waveform exposure start threshold value (228,238,428,528, 1004,1231)；And

Exposure in response to detecting the electrical characteristic in the periodicity power waveform starts threshold value to generate the exposure Light starts control signal.

31. method as claimed in claim 30, including：The beginning threshold value in the periodicity power waveform is detected Afterwards, the exposure is generated with predetermined time delay and starts control signal.

32. method as claimed in claim 30, wherein, the camera is terminated in response to exposure termination control signal so that institute Magazine photosensor array is stated to the light that sends or reflect from the welding region or from the feature in the welding region Can exposure.

33. method as claimed in claim 32, including：Detect the exposure termination of the electric characteristic in the weld power waveform Threshold value, and in response to detecting the exposure termination threshold value in the periodicity power waveform to the camera generation exposure Termination signal, to terminate so that the magazine photosensor array is to from the welding region or from the weld zone The luminous energy exposure that feature in domain sends or reflected.

34. method as claimed in claim 32, including：The electrical characteristic in the periodicity power waveform is detected Exposure start threshold value after, the exposure termination control signal is generated with predetermined time delay.

35. one kind is used for during the welding process powered by periodicity power waveform (136,202,302,402,502,1202) The method for the special characteristic (103,104,106,107,108,110,111,112,113) checked in welding region (109), in institute State electrical characteristic (V, I) in periodicity power waveform periodically to change, methods described includes：

Camera (126) is focused on the welding region, wherein the camera starts control signal to start in response to exposure So that the magazine photosensor array exposes to the luminous energy for sending or reflecting from the feature in the welding region A series of exposure periods (204,304,404,1004,1224)；

During these periods the periodicity power waveform first stage generation it is described exposure start control signal with Just so that the photosensor array exposes to the luminous energy for sending or reflecting from the welding region, so as to produce from the system A series of composographs (255,398,478,578,1032,1260) of row exposure period；

By the series of composite images (255,398,478,578,1032, the 1260) crossfire of the feature to display device with In the feature in the welding region be subject to as described feature during the first stage of the periodicity power waveform Existing ground video is shown；And

Change these exposure periods to be allowed to occur in the different phase of the periodicity power waveform, until these time for exposure Section was appeared in the stage that the special characteristic is present, and was shown so that the special characteristic is illustrated in the video (140) in the series of composite images (255,398,478,578,1032,1260) in.

36. one kind is used for a series of composographs (255,398,478,578,1032, the 1260) next life produced from camera (126) Into the method for the video of welding process, methods described includes：

To the first operator scheme of video camera (126) using multiple operating parameters to generate multigroup list of the welding process One image (204 ', 304 ', 404 ', 504 ', 1224 ')；

Using the waveform created by the arc welder for performing the welding process come in the following manner by multigroup single figure As synchronous with the welding process：

There is provided many in response to first group position (228,352,428,528,1217) place of the operating parameter on the waveform Individual first trigger pulse, these first trigger pulses are used for the shutter for opening the camera so that multigroup single figure Every single image in any given group as in has on the waveform in other described single images organized The correspondence image that is triggered of substantially the same position；

There is provided many in response to second group position (230,354,430,530,1217) place of the operating parameter on the waveform Individual second trigger pulse, these second trigger pulses be used to close the shutter on the camera so that described multigroup Every single image in any given group in single image has in other described single images organized to be had therewith There is the correspondence image of substantially the same exposure period；

By the way that the single image in multigroup single image to be combined to create the combination image, so that from institute State multigroup single image and create the series of combination image；

The video of the welding process is generated from the series of combination image；

The video of the welding process is analyzed to provide the analysis to the welding process；And

The welding process is changed in response to the analysis.

37. method as claimed in claim 36, wherein, the process for producing the first trigger pulse is included for all described Single image produces the first trigger pulse that the substantially the same position on the waveform occurs.

38. method as claimed in claim 36, wherein, the process for producing the first trigger pulse is included in multigroup list The first trigger pulse that the diverse location on the waveform occurs is produced within each group in one image.

39. method as claimed in claim 37, wherein, the process for producing the second trigger pulse is included for all described Single image produces the second trigger pulse that the substantially the same position on the waveform occurs.

40. method as claimed in claim 38, wherein, the process for producing the second trigger pulse is included for all described Single image produces the second trigger pulse that the substantially the same position on the waveform occurs.

41. method as claimed in claim 37, wherein, the process for producing the second trigger pulse is included in multigroup list The second trigger pulse that the diverse location on the waveform occurs is produced within each group in one image.

42. method as claimed in claim 38, wherein, the process for producing the second trigger pulse is included in multigroup list The second trigger pulse that the diverse location on the waveform occurs is produced within each group in one image.

43. method as claimed in claim 36, further comprises showing the video.

44. method as claimed in claim 36, further comprise illuminating background area around the welding process with lamp, make The background area is obtained in the video to occur.

45. method as claimed in claim 36, wherein, the process for producing the first trigger pulse include given threshold and Detect when the waveform reaches the threshold value.

46. method as claimed in claim 45, wherein, the process for producing the second trigger pulse include given threshold and Detect when the waveform reaches the threshold value.

47. method as claimed in claim 45, wherein, the process for producing the second trigger pulse is including the use of from described the The delay period that one trigger pulse is calculated.

48. method as claimed in claim 36, further comprises to the second operator scheme of the video camera using multiple Operating parameter.

49. a kind of system for being used to generate the video of welding process, including：

Wire feed welding machine (102), the wire feed welding machine is welded multiple metal weldments (110,112) to produce weld seam (103)；

The source of welding current (132), the source of welding current produces the power supply wave shape (136) for being applied to the welding machine；

Camera (126) with shutter, the camera is aligned for responsively generating the multigroup single of the welding process Image；

Controller (124), the controller sense the power supply wave shape and on the waveform first group of position (228, 352,428,528,1217) place produces multiple first trigger pulses, and these first trigger pulses be used to open on the camera The shutter so that every single image in any given group in multigroup single image is all described There is the correspondence image that the substantially the same position on the waveform is triggered in multigroup single image；And in the waveform On second group of position (230,354,430,530,1217) place produce multiple second trigger pulses, these the second trigger pulse quilts For closing the shutter on the camera so that every institute in any given group in multigroup single image State single image starts all in multigroup single image with the substantially the same position on the waveform, base The correspondence image of equal exposure period (204) in sheet；The controller carries out logical operation to combine every group of single image In single image, to produce the combination image that is suitable for showing and analyzes.

50. system as claimed in claim 49, wherein, the controller produces first trigger pulse so that at every group In single image, first group of position on the waveform is substantially the same.

51. system as claimed in claim 49, wherein, the controller produces first trigger pulse so that at every group In single image, at least some positions in first group of position on the waveform are different.

52. system as claimed in claim 50, wherein, the controller produces second trigger pulse so that at every group In single image, second group of position on the waveform is substantially the same.

53. system as claimed in claim 50, wherein, the controller produces second trigger pulse so that at every group In single image, at least some positions in second group of position on the waveform are different.

54. system as claimed in claim 51, wherein, the controller produces second trigger pulse so that at every group In single image, at least some positions in second group of position on the waveform are different.

55. system as claimed in claim 49, further comprises the display for showing the combination image.

56. system as claimed in claim 49, further comprises lamp, these lamps illuminate weldment so that the weldment exists It is visible in the combination image.

57. system as claimed in claim 49, wherein, the controller senses the power supply wave shape and by by threshold value It is compared to produce first trigger pulse with the power supply wave shape.

58. system as claimed in claim 49, further comprises multiple shift registers, these shift registers will come from institute The pixel for stating multiple pixel streams of every image in each group in multigroup single image is alignd.

59. system as claimed in claim 49, wherein, the controller includes multiple comparators, and these comparators are based on picture The brightness value of element selects the pixel for the combination image.