DE112015005683T5 - Welding sight and control system - Google Patents

Abstract

A welding vision and control system (100) for an arc welding system (102), wherein the arc welding system is powered by a cyclic energy waveform (136, 202, 302, 402, 502, 1002, 1202) from a welding power supply (122) to provide an arc welding system Weld bead on a workpiece (110, 112) in a weld region (109), and the following comprises a camera (126) having a light sensor assembly which is directed to the weld region or feature (103, 104, 106, 107, 108, 110, 111, 112, 113) in the weld region, the camera being responsive to exposure initiation control signals for irradiating the light sensor assembly with light energy emitted or reflected from the weld region or feature in the weld region to a row of raw images (204 ', 304', 404 ', 504', 1004 ', 1224') of the weld region or feature in the weld region, and a vision system controller (124) having the Beli generated initiation control signals to the camera at a predetermined trigger point on a cyclic energy waveform.

Description

BACKGROUND

Welding is generally a manufacturing process that permanently bonds parts of materials, such as metals, by fusing the materials together. Such fusion of adjacent metal parts requires enough energy to melt the metal. Arc welding is a typical welding process in which the energy required to melt the metal is provided by a high voltage electric arc between at least one of the metal parts and a metal electrode which slowly melts away at the point where the electric arc comes out of the electrode around a puddle To form electrode metal, which merges with the adjacent metal parts. As the metals cool in the molten puddle and adjacent metal parts, the molten metals solidify to form a weld that permanently bonds the two metal parts together. Welding systems and techniques have been continuously improved over the years. For example, in gas tungsten arc welding (TIG), a non-consumable tungsten electrode is used to create the weld. In addition, in gas metal arc welding (MIG), a wire feed gun is used which guides an electrode wire into the weld zone at an adjustable rate, and some of these welding processes alternately move the electrode wire away from the molten puddle and away from the molten puddle as droplets of molten material flow away Electrode wire at the distal end of the electrode wire, where the arc is formed form. Also, some types of limited-automation welding systems have been developed that have reduced the need for manual welding in many industrial welding environments. Improvements to the power supplies of MIG and TIG welding systems have also resulted in welders that are easy to handle and provide high quality welds.

The electric arcs, which generate the heat needed to melt the metals during arc welding, also produce very intense, high-energy radiation emissions, for example, extremely bright visible light as well as ultraviolet and infrared radiation. This radiation is so intense that a person is unable to observe a current arc welding process without an extreme risk of flash burns, where high intensity ultraviolet radiation can cause inflammation of the cornea of the eye and burn the person's retina. Therefore, welders must wear welding goggles or welding hoods with dark UV filter face shields to avoid these types of eye damage. These facial discs are so dark that a person can not perceive normal visible light through them. Therefore, welders have to remove the hood so that they can see something if they do not weld, but in any case they have to put the hood back on to protect the eyes before the welding arc is ignited to start a weld. Meanwhile, faceplates have been developed for welding hoods, which instantly darken when intense ultraviolet light hits them.

BRIEF SUMMARY OF THE INVENTION

A welding vision and control system for an arc welding system, wherein the arc welding system is powered by current through a cyclic energy waveform from a welding power supply to create a weld bead on a workpiece in a weld region, and comprising: (i) a camera having a A light sensor assembly focused on the weld region or feature in the weld region, the camera responsive to exposure initiation control signals for irradiating the light sensor assembly with light energy emitted or reflected from the weld region or feature in the weld region And (ii) a vision system controller that generates the exposure initiation control signals to the camera at a predetermined trip point on the cyclic energy waveform. In one embodiment, the vision system controller detects when an electrical characteristic in the cyclic energy waveform matches an exposure initiation threshold and, in response, generates the exposure initiation control signals to the camera. In another embodiment, the welding power supply outputs the exposure initiation control signals to the camera to initiate the exposure at the predetermined trigger point on the cyclic energy waveform. In another embodiment, the welding power supply outputs a trip signal to the vision system controller corresponding to the predetermined trip point on the cyclic energy waveform, and the vision system controller generates the exposure initiation control signals to the camera in response to the trip signal. In a further embodiment, the predetermined trigger point on the cyclic energy waveform is manually or automatically adjustable.

A method for generating a series of raw images of a weld region or a Feature in the weld region during a welding process powered by a cyclic energy waveform in which an electrical property varies cyclically includes: (i) focusing a camera on the weld region or feature in the weld region, and (ii) Triggering the camera to irradiate a light sensor array in the camera with light energy radiated or reflected from the weld region or feature in the weld region over a sequence of exposure periods to pre-defined the raw images of the weld region or feature in the weld region Generate phases of the cyclic energy waveform.

A method of viewing a particular feature in a weld region during a welding process that is powered by a cyclic energy waveform in which an electrical property varies cyclically comprises: (i) focusing a camera on the weld region, wherein the camera is for exposure initiation Control signals for initiating the exposure of a light sensor array in the camera to light energy emitted or reflected by the feature in the weld region over a sequence of exposure periods, (ii) generating the exposure initiation control signals for irradiating the light sensor array with light energy generated by is emitted or reflected during the periods of a first phase of the cyclic energy waveform for producing a series of composite images from the sequence of exposure periods, (iii) streaming the series of composite images of the Feature on a display device for a video display of features in the weld region as the features exist during the first phase of the cyclic energy waveform, and (iv) changing the exposure periods to occur in other phases of the cyclic energy waveform until the exposure periods in one Phase, in which the particular feature exists, so that the particular feature in the series of composite images is shown on the video display device.

An embodiment of the present invention may therefore include a method of generating a video of a welding process from a series of combined images generated by a camera, comprising: applying a plurality of operating parameters to a first operating mode of a video camera to generate a plurality of sets of frames welding process; Using a waveform generated by an arc welder performing the welding process to synchronize the plurality of sets of frames with the welding process by: providing first trigger pulses at a first set of positions on the waveform in response to the operating parameters used therefor to open the shutter of the camera so that each of the frames in each set of frames of frames has a corresponding image in other sets of frames that has been triggered at substantially the same position on the waveforms; Generating second trigger pulses at a second set of positions on the waveform in response to the operating parameters used to close the shutter of the camera such that each of the frames in each set of frames of frames forms a corresponding image in other sets of frames has, which has substantially the same exposure period; Generating the series of combined images from the plurality of sets of frames by combining the frames in the sets of frames to produce the combined images; Generating the video of the welding process from the series of combined images; Analyzing the video of the welding process to provide an analysis of the welding process; and modifying the welding process in response to the analysis.

An embodiment of the present invention may further include a system for generating a video of a welding process, comprising: a wire feeding welder that welds metallic welds to form a weld; a welding power supply that generates a power supply waveform that is input to the welder; a camera having a shutter which is aligned to produce [...] in response to several sets of frames of the welding process; a control unit that detects the power supply waveform and generates first trigger pulses at a first set of positions on the waveform that are used to open the shutter of the camera so that each of the frames in each set of the plurality of sets of frames has corresponding images in the frame has a plurality of sets of frames fired at a substantially same position on the waveform and generates second trigger pulses at a second set of positions on the waveform that are used to close the shutter of the camera so that each of the frames in each set of the plurality of sets of frames, having corresponding frames in the plurality of sets of frames having substantially equal exposure periods beginning substantially at the same position on the waveform, the control unit performing logical operations to capture frames in each set of frames One combine images to create combined images suitable for display and analysis.

BRIEF DESCRIPTION OF THE DRAWINGS

1 FIG. 12 is a schematic block diagram of an exemplary embodiment of a weld vision and control system; FIG.

1A is an enlarged perspective view of the welding region of a welding system,

2 FIG. 4 is a diagrammatic view of an exemplary progressive exposure technique using a single threshold trigger point; FIG.

3 FIG. 12 is a diagrammatic view of an exemplary progressive exposure technique having a trigger point delayed from a threshold; FIG.

4 FIG. 4 is a diagrammatic view of an exemplary constant exposure technique using variable trigger delay; FIG.

5 FIG. 4 is a diagrammatic view of an exemplary variable exposure technique using a variable trigger delay; FIG.

6A FIG. 3 is a flowchart illustrating the operation of the exemplary weld vision and control system of FIG 1 illustrates

6B FIG. 4 is a flowchart illustrating the operation of the vision system controller; FIG.

7 illustrates an exemplary system for initiating an exposure in a camera,

8th FIG. 12 is a diagrammatic illustration of an exemplary system that may be used to temporally align the pixel streams of each of the exposures, as in FIGS 2 - 5 illustrates

9 FIG. 4 is a block diagram illustration of an exemplary embodiment of an image combiner; FIG.

9A 12 is a diagrammatic illustration of an example system for selecting pixels that are neither saturated nor dark,

9B Fig. 2 is a diagrammatic illustration of an exemplary bright area pixel selection system;

9C FIG. 12 is a diagrammatic illustration of an exemplary dark area pixel selection system; FIG.

10 Figure 4 is a diagrammatic view of an exemplary raw image merge to produce a composite image;

11 Figure 4 is a diagrammatic view of an exemplary temporal pixel alignment system;

12A FIG. 12 is a graph illustrating exemplary DC energy waveforms and example welding phenomena corresponding to the phase of the energy waveform. FIG.

12B . 12C and 12D FIGs. are diagrams illustrating an exemplary phased-array imaging system, and FIG

13 Figure 3 is a diagrammatic illustration of an exemplary manual weld vision system.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

An exemplary welding vision and control system 100 that is capable of taking pictures, for example a composite picture 140 To generate, fuse and display a welding process and to use such images for feedback and control of the welding process is shown in the schematic block diagram in FIG 1 illustrated. The exemplary weld vision and control system 100 is in 1 with an exemplary arc welding system 102 , for example, a gas-metal arc (MIG) system. However, the weld vision and control system can 100 also be used with other welding systems, such as manual metal arc welding (also commonly known as bar welding), flux cored arc welding, submerged arc welding, gas tungsten (TIG) welding, oscillation wire welding, cold metal transfer (CMT) welding, and others. In the exemplary MIG arc welding system 102 becomes a metal wire electrode 106 through a wire feed mechanism 120 from a wire source 118 through a tip (not visible) inside a welding nozzle 104 in a sweat region 109 pushed forward, where two metal parts, for example, metallic workpieces 110 . 112 to be welded together. A welding power supply 122 generates a waveform 136 electrically connected to the wire electrode 106 is connected. The metallic workpieces 110 . 112 become electric with the welding power supply 122 grounded, making one through the power supply 122 output voltage an electric arc 107 between the wire electrode 106 and the metallic workpieces 110 . 112 generated. The arc 107 generates one plasma 108 , which is highly conductive, between the wire electrode 106 the metallic workpieces 110 . 112 , The continued application of the voltage gives a strong flow of current through the plasma 108 between the distal end of the wire electrode 106 and the workpieces 110 . 112 upright, whereby enough heat is generated to the metal at the distal end of the wire electrode 106 as well as some metal on the workpieces 110 . 112 to melt where the flow of current near the wire electrode 106 concentrated, creating a melting zone 113 in the workpieces 110 . 112 arises. droplet 121 ( 1A of molten metal from the distal end of the wire electrode 106 form a metal puddle 111 with the molten metal in a molten zone 113 the workpieces 110 . 112 melts while a gas supply 116 an inert or semi-inert blanket gas stream from a gas source 114 through the welding nozzle 104 to protect the weld from contamination. While the welding nozzle 104 and the wire electrode 106 in the direction of the arrow 105 move, cool the metals that are in the sweat puddle 111 and the melting zone 113 stay behind, get off and become firm, creating a solid-metallic weld bead 103 arises, which the two workpieces 110 . 112 permanently connected.

The arc 107 and the flow of current through the plasma 108 in the exemplary MIG welding system 102 generate, as with other arc welding systems, a high-intensity electromagnetic radiation, for example, extremely bright visible light and ultraviolet and infrared radiation. This radiation is so intense that it is not possible for a person to enter the sweat area 109 to look at a current arc welding process without an extreme risk of eye damage, such as flash burns, where high intensity ultraviolet radiation can cause inflammation of the cornea of the eye and burn the retina. That's why welders have to use welding goggles or welding hoods (in 1 not shown) with dark UV filter face shields to prevent eye damage. These facial discs are so dark that a person can not perceive normal visible light through them. This is why welders have to remove the hood if they are not welding so they can see something, but in any case they need to put the hood back on to protect the eyes before the welding arc is ignited to start a weld to the highly intense one to attenuate visible light and extreme ultraviolet radiation to lower intensity levels that are tolerated by a person's eyes. The person may perceive the residual light from the brightest portions and features of a running welding process that is still penetrating through the dark glasses or face-plate, for example the arc 107 and the plasma 108 but other features, such as the cooling bead 103 , the outer areas of the melting zone 113 and adjacent portions of the metallic workpieces 110 . 112 in the welding area 109 that do not emit or reflect this intense radiation are not recognizable by such dark glasses or faceplate at all. Therefore, the ability of a person is limited to all the features and processes in the sweat region 109 to see and assess in real-time, to be informed about the welding process and to be able to assess its course and its quality. Likewise, conventional cameras do not have the dynamic range necessary to capture images of both the brightest features in a weld region 109 as well as the darker features in the weld region 109 at the same time, in particular to display such features in real time during the course of the welding process. Aperture settings that would allow enough light for a camera's light sensor array or photographic film to pick up the darker features in the weld region would also allow so much of the extreme, high intensity light of the brightest features to enter such parts of the high intensity light Overexposing the film or light sensor array exposed to the brightest light, thereby reducing those portions of the captured image of the weld region 109 would be meaningless and useless, while aperture settings that attenuate the light enough to avoid overexposing the image sensors or the film to the brightest light will not allow the image sensors or the film to image the darker portions of the weld region 109 take.

In contrast, the exemplary weld vision and control system produces 100 , this in 1 is shown and described in more detail below, composite images showing all features in the weld region 109 in areas of visible light that can be perceived by the human eye in real time during the course of the welding process and that can be processed and used for automatic welding machine control to monitor and optimize welding quality. For example, those provided by the exemplary weld vision and control system 100 generated composite images to monitor and assess the welding process and to adjust welding parameters, such as voltage and / or current of the exemplary arc welding system 102 , Position and speed of the welding nozzle 104 and the top (in 1 not seen) with respect to the workpieces 110 . 112 , the supply rate of the consumable wire electrode 106 in the welding area 109 . the size of the sweat puddle 111 and other parameters, that of the welding system 102 can improve drawn welds. The composite images may be viewed by a user who can adjust the parameters, or the composite images may be processed by machine imaging and pattern recognition techniques capable of automatically adjusting parameters of the welding process. The generated composite images can also be used in manual welding. For example, as in 13 illustrated and will be explained in more detail below, welding hoods that are used in manual welding, be equipped with a display device that allows a welder, the composite images of the welding region 109 , including all features such as welding nozzle 104 , Wire electrode 106 , Electric arc 107 , Plasma 108 , Sweat puddle 111 , Melting zone 113 and adjacent sections of the workpieces 110 . 112 to look in real time while the weld bead 103 is pulled. These capabilities are achieved by creating a wider visible spectrum or dynamic range of the image by fusing (combining) individual images electronically with different exposures, in different phases, and over different periods of time during the power supply waveform 136 were recorded, as will be explained in more detail below. The composite images may also be phased to provide one or more specific features in the weld region in real time 109 to isolate and display, for example, a droplet 121 made of molten metal, which consists of the consumable wire electrode 106 at one or more positions between the wire electrode 106 and the sweat puddle 111 is formed, as described in more detail below.

We stay with you 1 , The welding power supply 122 can be controlled to match the energy waveform 136 with various electrical parameters, such as current, voltage, impedance, frequency, waveform, etc., depending on the metals to be welded, the electrodes used, the desired weld properties, environmental influences, etc. The welding power supply 122 can be independently controlled for these and other parameters, or it can be controlled by a vision system controller 124 be controlled as by the connection 125 in 1 is indicated. The vision system controller 124 , which may include a programmable computer or a series of logic circuits, such as FPGAs or state machines, may also receive signals from the welding power supply 122 received as through the control connection 125 is indicated, for example, signals for the power supply waveform 136 or for a trip point in the power supply waveform 136 stand, as explained in more detail below. The vision system controller 124 can also receive inputs from the power supply waveform 136 received, for example, a voltage or current detector 123 as by the connection 148 in 1 indicated. Voltage sensors and current detectors suitable for this application are well known and available on the open market. The vision system controller 124 can also use a robotic system control unit 142 be connected, the control signals to robot system actuators 144 generates the welding nozzle 104 and the electrode 106 in relation to the workpieces 110 . 112 move and position. There will be suitable mechanical linkage 146 provided to the robot system actuators 144 with the welding nozzle 104 , the electrode 106 and other components of the arc welding system 102 as the skilled person readily understands, so that a closer description of such linkage 146 and actuators 144 is not required for an understanding of the invention. A user interface 128 is with the vision system controller 124 connected to control signals in the vision system control unit 124 feed to the welding power supply 122 to configure it to a desired waveform 136 and the robotic system control unit 142 to desired inputs to the robot system actuators 144 to configure. The connection can be a hardwired connection or a wireless connection. The robot system control unit 142 may be a separate unit or part of the vision system control unit 124 be.

A digital camera 126 is next to the arc welding system 102 positioned where it targets one or more features in the weld region 109 can be focused, for example, the arc 107 and the adjacent wire electrode 106 and the sweat puddle 111 , or on the entire welding region 109 in which some or all of these features are located. If desired, an optional second digital camera can also be provided 127 for stereoscopic imaging, such as below for the cameras 1306 of in 13 illustrated manual welding system 1300 is described. Camera control, lighting, raw image production by the camera 126 , Processing techniques for generating composite images from the raw images and further information and descriptions for the camera 126 apply, also apply to the optional second camera 127 , The digital camera 126 is controlled to provide raw images of the features in the weld region 109 generated, including, for example, the welding nozzle 104 , the welding wire electrode 106 , the arc 107 , the plasma 108 , the droplet 121 ( 1A ), the sweat puddle 111 , the melting zone 113 , the welding bead 103 and adjacent sections of the workpieces 110 . 112 , In one embodiment, the digital camera becomes 126 by signals from the vision system controller 124 controlled as by the camera control connection 129 in 1 is indicated to the light sensor arrangement in the digital camera 126 to irradiate with light that of such features in the weld region 109 is emitted or reflected. In another embodiment, the digital camera is powered by signals from the welding power supply 122 controlled by the optional camera control connection 129 in 1 is indicated to the light sensor arrangement in the digital camera 126 to irradiate with light that of such features in the weld region 109 is emitted or reflected. As will be explained in more detail below, different exposures are used to generate different raw images of the weld and the surrounding area that are in the controller 124 fused together (combined) to create a composite image, such as the composite image 140 that on a display device 138 in the user interface 128 or in a different location. The raw images show the characteristics in the welding region 109 with different exposures. By fusing the images with different exposures, all or selected of the features in the weld region can be 109 be displayed and viewed simultaneously in a high dynamic range composite image, while some of the features in the weld region 109 too light and others too dark for a light sensor array to pick up in a single image with a single exposure. Due to the different light intensities resulting from the different features in the welding region 109 For example, a particular exposure of the light sensor assembly (not shown) in the camera may be emitted or reflected 126 allow a raw image of the arc 107 quite effectively while another exposure of the light sensor assembly in the camera 126 can allow a raw image of the molten metal droplet 121 at the melting distal end of the wire electrode 106 is generated to record more effectively. Another exposure may be the light sensor arrangement in the camera 126 allow a raw picture of the sweat puddle 111 and the melting zone 113 It can take another exposure, it can be the image sensor of the camera 126 allow to capture raw images of other peripheral features, such as adjacent portions of the workpieces 110 . 112 and the solidified bead 103 , By fusing these different raw images together in a composite image, all or selected of the important features in the weld region can 109 in the resulting composite image, for example, the composite image 140 in 1 , At the camera 126 mounted lamps 134 (lamps 135 on the optional camera 127 If desired, they may help to illuminate the background or peripheral features, such as the weld pieces 110 . 112 and the solidified bead 103 , and can shorten the required exposure time required to capture such background features in a raw image.

An in 2 illustrated exemplary exposure technique 200 for irradiating the light sensor arrangement (not shown) of the camera 126 to the welding region 109 ( 1 ). In this exemplary exposure technique 200 becomes a sequence of exposures of the camera's light sensor array 126 with the light energy coming from the sweat region 109 or certain features in the weld region 109 is emitted or reflected at respective initiation trigger points 228 . 240 . 252 . 264 . 232 . 244 . 256 . 268 . 236 . 248 . 260 . 272 on the power supply waveform for successive exposure periods 204 . 210 . 216 . 222 . 206 . 212 . 218 . 208 . 214 . 220 . 226 triggered a series of respective raw images 204 ' . 210 ' . 216 ' . 222 ' . 206 ' . 212 ' . 218 ' . 208 ' . 214 ' . 220 ' . 226 ' to generate the composite images 253 . 255 . 257 to create. As mentioned above, such composite images 253 . 255 . 257 for an ad, such as the composite image 140 that in the display device 138 in 1 or for automated control of the exemplary arc welding system 102 in 1 are processed. The type of in the exemplary exposure technique 200 in 2 illustrated energy waveform 136 ( 1 ) is a cyclic energy waveform 202 , The exemplary cyclic energy waveform 202 is sinusoidal, which helps to describe the principles of this exposure technique 200 although well suited is pulsed AC or DC power waveforms, including signals with specially adapted or specialized rise, peak, background and fade pitches and amplitudes, as commonly used in many modern welding systems, and this exposure technique 200 can be applied to and used with such pulsed energy waveforms, as will be apparent to those skilled in the art, having understood the principles of this technique. An example of the application of this technique to a cyclic DC pulse energy waveform is shown in FIGS 12A . 12B and 12C and will be described in more detail below.

In the temporal graph of the exemplary energy waveform 202 in 2 the time (t) extends along the abscissa (horizontal Axis), and the voltage (V) is shown in the vertical direction, ie, the ordinate. In this exemplary exposure technique 200 becomes a single threshold voltage level on the waveform 202 (For example, the exemplary voltage level at initiation trigger points 228 . 240 . 252 . 264 . 232 . 244 . 256 . 268 . 236 . 248 . 260 and 272 ) for initiating (triggering) the irradiation of the light sensor arrangement of the camera 126 ( 1 ) with light used by the welding region 109 is emitted or reflected, with the camera 126 Raw images of the weld region 109 or certain features in the weld region 109 as explained in more detail below. The person skilled in the art understands the technologies and implementations of electronic cameras, so that an extensive explanation of details about the camera 126 ( 1 ) is not needed for understanding this exposure triggering technique. We may leave it aside to note that today's electronic cameras have a generally two-dimensional array of light sensors (typically CMOS or CCD sensors), commonly referred to as light sensor arrays, which when light hits them, that of an object (for example, the welding region 109 or a feature in the weld region 109 ) is radiated or reflected, the light energy from the object into a raw image (for example the raw images 204 ' . 210 ' . 216 ' . 222 ' . 206 ' . 212 ' . 218 ' . 208 ' . 214 ' . 220 ' . 226 ' ) in a pixel array format in which each pixel in the pixel array has a pixel value of electrical type (e.g., voltage, current, resistance, etc.) representing the light energy absorbed by each light sensor in the light sensor array during exposure. Therefore, the light sensor assembly generates an electronic pixel array of pixel values representing the different light intensities emitted or reflected from the object. Such pixel arrays can be processed to produce a visual image of the object. The exposure time of the light sensor assembly to the light emitted or reflected from the object may be controlled by a mechanical shutter that opens and closes a shutter for a desired period of time, or may be controlled by a shutter like function, for example, by electronic transmission from pixel cell charges or voltages to a paired shaded double. Various electronic closure techniques may also be used to initiate and terminate exposures or light energy absorption periods. That is, although references to "opening and closing a shutter to initiate and end an exposure time" would be understood by one skilled in the art to mean an electronic shutter, "initiating and ending the exposure" is a more general term. Consequently, these two terms of closure or closure operations are synonymous and can be used interchangeably. In 2 are several exemplary exposure periods 204 . 210 . 216 . 222 . 206 . 212 . 218 . 224 . 208 . 214 . 220 and 226 illustrated. These example exposure periods 204 . 210 . 216 . 222 . 206 . 212 . 218 . 224 . 208 . 214 . 220 and 226 have respective initiation trigger points 228 . 240 . 252 . 264 . 232 . 244 . 256 . 268 . 236 . 248 . 260 and 272 and respective termination trigger points 230 . 242 . 254 . 266 . 234 . 246 . 268 . 270 . 238 . 250 . 262 and 274 ,

In an example implementation of the exemplary exposure technique 200 in 2 is the vision system controller 124 for controlling the camera 126 used in this exemplary implementation, with the welding power supply 122 (for example, about the connection 125 in 1 ) or with an energy waveform sensor 123 (for example, about the connection 148 in 1 ) to provide a varying electrical characteristic, for example voltage levels or current levels, in the energy waveform 136 in 1 that in the example of 2 the sinusoidal energy waveform 202 is to monitor. If a predetermined voltage or current threshold in the energy waveform 202 is detected, the vision system control unit generates 124 an initiation control signal to the camera 126 to the irradiation of the light sensor assembly in the camera 126 to initiate with the light energy coming from the welding region 109 or features in the weld region 109 is emitted or reflected. The threshold may in principle be a voltage threshold, a current threshold, an impedance threshold or some other parameter in the energy waveform 202 but for the sake of simplicity, the graph of 2 a graph of the voltage versus time for the energy waveform 202 with the understanding that it could be other electrical property as well. Accordingly, the voltage reaches when on the energy waveform 202 rises, the initiation threshold voltage level, such as the initiation threshold voltage level, at the initiation trigger points 228 . 240 . 252 . 264 . 232 . 244 . 256 . 268 . 236 . 248 . 260 and 272 is illustrated. The vision system controller detects when these initiation threshold voltage values are reached and the voltage on the energy waveform 202 rises, and in response generates the initiation control signal to the camera 126 as stated above. The detection of the initiation threshold voltage level may be accomplished by a simple comparison circuit in which the detected voltage is at the predetermined initiation threshold voltage value in the vision system controller 124 is compared to the generation of the Initiate initiation control signal when the voltage of the energy waveform 202 increases. The initiation threshold voltage level can be easily set in the vision system controller 124 via the user interface 128 can be adjusted so that the initiation threshold voltage can be easily adjusted by the user, or can be provided in any other convenient manner.

The exposure periods 204 . 210 . 216 . 222 . 206 . 212 . 218 . 224 . 208 . 214 . 220 . 226 in 2 illustrate the exposure periods during which the light sensor arrangement in the camera 126 is irradiated with the light energy coming from the welding region 109 is emitted or reflected and that is generated by the welding process or originates from external illumination, as will be described in more detail below. As explained above, the camera generates 126 the respective raw pictures 204 ' . 210 ' . 216 ' . 222 ' . 206 ' . 212 ' . 218 ' . 208 ' . 214 ' . 220 ' . 226 ' on the basis of the light energy generated by the light sensor arrangement of the camera 126 during the respective exposure periods 204 . 210 . 216 . 222 . 206 . 212 . 218 . 224 . 208 . 214 . 220 and 226 is absorbed. The first set of four raw images 204 ' . 210 ' . 216 ' . 222 ' is fused together in a manner which will be explained in more detail below to the first composite image 253 to create. Likewise, the second sentence becomes four raw images 206 ' . 212 ' . 218 ' . 224 ' fused together in the same way to the second composite image 255 to create. The third movement of four raw images 208 ' . 214 ' . 220 ' . 226 ' is also fused together in the same way to the third composite image 257 to create. Of course, there will be more composite images symbolically represented by dots N in 2 represented by the vision system control unit 124 ( 1 ) is generated from further raw images symbolically represented by the points n 'in 2 While the welding process is continued, so that a video of the welding process from a stream of composite images 253 . 255 . 257 , ..., N can be generated while the arc welding system 102 along the workpieces 110 . 112 moves as indicated by the arrow 105 in 1 is indicated.

As in 2 is the first exposure period 204 for the first raw picture 204 ' for generating the first composite image 253 is used, the same amount of time and occurs during the same phase of the energy waveform 202 like the first exposure period 206 for the first raw picture 206 ' for generating the second composite image 255 is used. Likewise, the first exposure period is 208 for the first raw picture 208 ' for generating the third composite image 257 is used, the same amount of time and occurs during the same phase of the energy waveform 202 like the first and second exposure periods 204 . 206 , Likewise, the second exposure periods are 210 . 212 . 214 for the raw images 210 ' . 212 ' . 214 ' for generating the respective composite images 253 . 255 . 257 are used, equal to each other, and are performed among each other during the same phase of the energy waveform 202 , Likewise, the third exposure periods are 216 . 218 . 220 for the raw images 216 ' . 218 ' . 220 ' for generating the respective composite images 253 . 255 . 257 are also equal to each other and are performed among each other during the same phase of the energy waveform 202 , Furthermore, the fourth exposure periods 222 . 224 . 226 for the raw images 222 ' . 224 ' . 226 ' for generating the respective composite images 253 . 255 . 257 are also equal to each other and are performed among each other during the same phase of the energy waveform 202 ,

As in 2 shown, each of the exposure periods 204 . 210 . 216 . 222 for the respective raw images 204 ' . 210 ' . 216 ' . 222 ' at the same threshold voltage level on the energy waveform 102 initiated, ie at the respective initiation trigger points 228 . 240 . 252 . 264 but they last through a larger phase of energy waveform 202 through, which extends over a longer period of the welding process. That's why every single raw picture has 204 ' . 210 ' . 216 ' . 222 ' for generating the first composite image 253 is used, a progressively longer exposure period 204 . 210 . 216 . 222 at the welding area 109 ( 1 ) or features in the weld region 109 , The same principle applies to the exposure periods 206 . 212 . 218 . 224 for the raw images 206 ' . 212 ' . 218 ' . 224 ' for generating the second composite image 255 used and for the exposure periods 208 . 214 . 220 . 226 for the raw images 208 ' . 214 ' . 220 ' . 226 ' for generating the third composite image 257 be used.

As explained above, in the in 2 Illustrated exemplary exposure technique 200 all exposure periods 204 . 210 . 216 . 222 . 206 . 212 . 218 . 224 . 208 . 214 . 220 . 226 upon detection of a predetermined initiation voltage threshold level when the voltage of the energy waveform 202 increases. When it is detected that the voltage in the energy waveform 202 rises to the previously set initiation voltage threshold level, the vision system controller issues 124 an initiation trigger signal to the camera 126 out, prompting the camera 126 the irradiation of the light sensor arrangement with the light energy of features in the welding region 109 is emitted or reflected ( 1 ), as explained above. Therefore, the detection of such an initiation voltage level at the first initiation trip point 228 in that the vision system control unit 124 an initiation control signal to the camera 126 will spend the first exposure period 204 to initiate. Likewise, the detection of such initiation voltage level at the second initiation trip point 240 in that the vision system control unit 124 an initiation control signal to the camera 126 returns to the second exposure period 210 to initiate. The detection of such an initiation voltage level at the third initiation trip point 252 initiates the vision system control unit 124 , an initiation control signal to the camera 126 to spend the third exposure period 216 to initiate; the detection of such initiation voltage level at the fourth initiation trip point 264 initiates the vision system control unit 124 , an initiation control signal to the camera 126 to spend the fourth exposure period 222 to initiate; the detection of such an initiation voltage level at the fifth initiation trip point 232 initiates the vision system control unit 124 , an initiation control signal to the camera 126 to spend the fifth exposure period 206 to initiate; the detection of such initiation voltage level at the sixth initiation trip point 244 initiates the vision system control unit 124 , an initiation control signal to the camera 126 output to the sixth exposure period 212 to initiate; the detection of such initiation voltage level at the seventh initiation trip point 256 initiates the vision system control unit 124 , an initiation control signal to the camera 126 to spend the seventh exposure period 218 to initiate; the detection of such initiation voltage level at the eighth initiation trip point 268 initiates the vision system control unit 124 , an initiation control signal to the camera 126 to spend the eighth exposure period 224 to initiate; the detection of such initiation voltage level at the ninth initiation trip point 236 initiates the vision system control unit 124 , an initiation control signal to the camera 126 to spend the ninth exposure period 208 to initiate; the detection of such an initiation voltage level at the tenth initiation trip point 248 initiates the vision system control unit 124 , an initiation control signal to the camera 126 spend the tenth exposure period 214 to initiate; the detection of such initiation voltage level at the eleventh initiation trip point 260 initiates the vision system control unit 124 , an initiation control signal to the camera 126 to spend the eleventh exposure period 220 to initiate; and detecting such an initiation voltage level at the twelfth initiation trip point 272 initiates the vision system control unit 124 , an initiation control signal to the camera 126 to spend the twelfth exposure period 226 to initiate. This process continues as long as the user wants to continue imaging for the welding process.

The vision system controller 124 also controls the duration of the respective first to twelfth exposure periods 204 . 210 . 216 . 222 . 206 . 212 . 218 . 224 . 208 . 214 . 220 . 226 and beyond. Accordingly, the vision system controller generates 124 - and sends to the camera 126 ( 1 ) - an exposure completion control signal a certain period after each exposure initiation control signal, whereupon the camera 126 the irradiation of the light sensor assembly with the light coming from the welding region 109 emitted or reflected, finished. As in 2 is the vision system controller 126 programmed to generate termination control signals and at the respective times that the termination trigger points 230 . 242 . 254 . 266 . 234 . 246 . 258 . 270 . 238 . 250 . 262 . 274 on the energy waveform 202 correspond to the camera 126 to send to the respective exposure periods 204 . 210 . 216 . 222 . 206 . 212 . 218 . 224 . 208 . 214 . 220 . 226 to end. The vision system controller 124 may be programmed to generate the exposure completion control signals and to the camera 126 by either: (i) counting the elapsed time after each exposure initiation control signal is triggered at the respective initiation trigger points 228 . 240 . 252 . 264 . 232 . 244 . 256 . 268 . 236 . 248 . 260 and 272 and - after elapse of a predetermined period after initiation of each such initiation control signal, generating the exposure termination control signal, or (ii) determining when the voltage on the energy waveform 102 coincident with a predetermined termination voltage threshold, and upon detection of such coincidence, generating the exposure completion control signal. Examples of such predetermined periods and preset termination thresholds for triggering the vision system controller 124 to generate the exposure completion control signals correspond to the completion trigger points 230 . 242 . 254 . 266 . 234 . 246 . 258 . 270 . 238 . 250 . 262 . 274 on the energy waveform 202 in 2 , Again, as explained above and in 2 shown the raw images 204 ' . 210 ' . 216 ' . 222 ' that are used for the first composite image 253 for example, progressively longer, thereby minimizing the likelihood of sensors in the light sensor assembly in the shortest exposure period 204 for the first raw picture 204 ' through the most intense light energy from the brightest features, for example the arc 107 and the plasma 108 , the welding region 109 ( 1 ) are overexposed while maximizing the likelihood that sensors in the light sensor array will capture some of the light energy from the darker features, such as the weld bead 103 and the workpieces 110 . 112 , in the sweat region 109 during the longest exposure period 222 for the raw picture 222 In addition, the probability increases that the second and third raw images 210 ' and 216 ' that with the intermediate exposure periods 210 . 216 provide good views of features that radiate or reflect light energy of moderate intensity, such as the electrode 106 , the sweat puddle 111 or the melting zone 113 , Likewise, the raw pictures 206 ' . 212 ' . 218 ' . 224 ' which are used for the second composite image 255 to generate, and the raw images 208 ' . 214 ' . 220 ' . 226 ' that are used for the third composite image 257 for the same reasons different, for example, progressively longer. Furthermore, the merges into 2 Although exemplary exposure and fusing technique illustrated four raw images to each composite image 253 . 255 . 257 but more or less than four raw images could be merged to produce the composite images. The aperture and the sensitivity of the camera 126 may also be varied for some or all exposures to increase the likelihood that different features or portions of the weld region 109 during each exposure period in a usable way. Furthermore, the optional dynamic dimming disc 130 ( 1 ), as will be explained in more detail below, the intensities of the light energy of the weld region 109 holding the camera 126 Achieved, dampen and vary in the likelihood of increasing various features or sections of the sweat regions 109 can be effectively picked up by the light sensor assembly for one or more of the raw images used to produce the composite images.

The raw pictures 204 ' . 210 ' . 216 ' . 222 ' be through the camera 126 are added to the vision system control unit 124 are transmitted and then by the vision system control unit 124 fused to the first composite image 253 to create. Likewise, those by the camera 126 recorded raw images 206 ' . 212 ' . 218 ' . 224 ' to the vision system controller 124 transmitted and merged to the second composite image 255 to generate, and the raw images 208 ' . 214 ' . 220 ' . 226 ' are merged to the third composite image 257 to create. The composite pictures 253 . 255 . 257 be through the vision system control unit 124 according to techniques described below and in the flow chart of 6 are shown. The composite pictures 253 . 255 . 257 can then on the user interface 128 be displayed and stored in a memory in the control unit 124 is stored, or stored elsewhere, for later viewing and analysis, and parameters of the arc welding system 102 to vary in order to improve the quality of other properties of the weld. A series of composite images 253 . 255 . 257 , ..., N can also be displayed in rapid succession to provide a video of the welding process in real time or to be stored and subsequently viewed. The composite pictures 253 . 255 . 257 can also be used with machine imaging and pattern recognition techniques to provide automated real-time control of the arc welding system 102 as will be explained in more detail below.

Another exemplary progressive exposure technique 300 is in 3 with initiation trigger points 352 . 364 . 376 . 388 . 356 . 368 . 380 . 392 . 360 . 372 . 384 . 395 Figure 4 illustrates the detection of an exposure initiation threshold 303 on the power supply waveform 302 are delayed. For the sake of simplicity, and for comparison, the in 3 illustrated exemplary power supply waveform 302 a sine waveform similar to the sine waveform 202 in 2 but other types of waveforms could also be used, such as pulsed AC or DC waveforms, including shaped waveforms with specially adapted or specialized slope, peak, background, and fading slopes, and amplitudes commonly used in many modern welding systems. with this technique 300 be used. The exposure initiation threshold 303 in the example of 3 is a voltage value on the energy waveform 302 but it could also be a current value, an impedance value, or some other electrical property in, or related to, the energy waveform 302 be. The exposure initiation threshold voltage 303 is through the vision system control unit 124 at voltage threshold points 328 . 330 . 332 . 334 . 336 . 338 . 340 . 342 . 344 . 346 . 348 . 350 on the energy waveform 303 detected. Instead, however, an exposure initiation control signal immediately upon detection of the initiation threshold voltage 303 trigger the vision system controller 124 a delay for generating the exposure initiation control signals at a later stage on the energy waveform 302 , for example at the initiation trigger points 352 . 364 . 376 . 388 . 356 . 368 . 380 . 392 . 360 . 372 . 384 . 395 on the energy waveform. Each of these Exposure initiation control signals are sent to the camera 126 sent to an irradiation of the light sensor arrangement in the camera 126 with the light energy coming from the sweat region 109 is emitted or reflected ( 1 ), for the respective exposure periods 304 . 310 . 316 . 322 . 306 . 312 . 318 . 324 . 308 . 314 . 320 . 326 to initiate the respective raw images 304 ' . 310 ' . 316 ' . 322 ' . 306 ' . 312 ' . 318 ' . 324 ' . 308 ' . 314 ' . 320 ' . 326 ' to create. The vision system controller 124 also generates, and sends, exposure completion control signals to the camera 126 to end the respective exposure periods 304 . 310 . 316 . 322 . 306 . 312 . 318 . 324 . 308 . 314 . 320 . 326 for the raw images 304 ' . 310 ' . 316 ' . 322 ' . 306 ' . 312 ' . 318 ' . 324 ' . 308 ' . 314 ' . 320 ' . 326 ' , As above for the example of 2 explains, the four raw images 304 ' . 310 ' . 316 ' . 322 ' fused together to form a first composite image 397 to create; the next four raw pictures 306 ' . 312 ' . 318 ' . 324 ' are merged together to form the second composite image 398 to create; and the next four raw pictures 308 ' . 314 ' . 320 ' . 326 ' are merged together to form the third composite image 399 to create.

As also above for the example of 2 explains, generates the vision system control unit 124 progressively longer exposure periods 304 . 310 . 316 . 322 for the raw images 304 ' . 310 ' . 316 ' . 322 ' that are used for the first composite image 397 to create. Likewise, the vision system controller generates 124 progressively longer exposure periods 306 . 312 . 318 . 324 for the raw images 306 ' . 312 ' . 318 ' . 324 ' which are used for the second composite image 398 and produces progressively longer exposure periods 308 . 314 . 320 . 326 that are used for the third composite image 399 to create. The respective exposure periods 304 . 306 . 308 for the first raw pictures 304 ' . 306 ' . 308 ' which are used for the respective composite images 397 . 398 . 399 each have the same duration and occur in the same phase of the energy waveform 302 , Likewise, the respective exposure periods have 304 . 306 . 308 for the second raw pictures 310 ' . 312 ' . 314 ' which are used for the respective composite images 397 . 398 . 399 each generate the same duration and occur in the same phase of the energy waveform 302 ; the respective exposure periods 304 . 306 . 308 for the third raw pictures 316 ' . 318 ' . 320 ' which are used for the respective composite images 397 . 398 . 399 each have the same duration and occur in the same phase of the energy waveform 302 ; and the respective exposure periods 322 . 324 . 326 for the third raw pictures 304 ' . 306 ' . 308 ' which are used for the respective composite images 397 . 398 . 399 each have the same duration and occur in the same phase of the energy waveform 302 , Accordingly, the exposure periods become 304 . 310 . 316 . 322 for the four raw pictures 304 ' . 310 ' . 316 ' . 322 ' that are used for the first composite image 397 at the respective termination points 354 . 366 . 378 . 390 on the energy waveform 302 completed; the exposure periods 306 . 312 . 318 . 324 for the next four raw images 306 ' . 312 ' . 318 ' . 324 ' which are used for the second composite image 398 are generated at the respective termination points 358 . 370 . 382 . 394 on the energy waveform 302 completed; and the exposure periods 308 . 314 . 320 . 326 for the next four raw images 308 ' . 314 ' . 320 ' . 326 ' that are used for the third composite image 399 are generated at the respective termination points 362 . 374 . 386 . 396 on the energy waveform 302 completed.

So if we have the exposure periods 204 . 210 . 216 . 222 . 206 . 212 . 218 . 224 . 208 . 214 . 220 . 226 in the example of 2 with the exposure periods 304 . 310 . 316 . 322 . 306 . 312 . 318 . 324 . 308 . 314 . 320 . 326 in the example of 3 compare, so are the raw images 304 ' . 310 ' . 316 ' . 322 ' . 306 ' . 312 ' . 318 ' . 324 ' . 308 ' . 314 ' . 320 ' . 326 ' which are used for the first, second and third composite images 397 . 398 . 399 in 3 in other phases of the energy waveform 302 as the phases of the energy waveform 202 in which the exposure periods 204 . 210 . 216 . 222 . 206 . 212 . 218 . 224 . 208 . 214 . 220 . 226 occur. As the intensities of light as well as the physical features passing through the welding system 102 in the welding area 109 ( 1 ), depending on the varying voltage, varying current, or varying impedance that is associated with the energy waveform, will be picked up by the camera 126 in the example of 3 generated raw images 304 ' . 310 ' . 316 ' . 322 ' . 306 ' . 312 ' . 318 ' . 324 ' . 308 ' . 314 ' . 320 ' . 326 ' other physical characteristics and light intensities in the weld region 109 on as the raw images 204 ' . 210 ' . 216 ' . 222 ' . 206 ' . 212 ' . 218 ' . 208 ' . 214 ' . 220 ' . 226 ' in the example of 2 , In addition, the delay in the example of 3 between the detections of the exposure initiation threshold voltage at the voltage threshold points 328 . 330 . 332 . 334 . 336 . 338 . 340 . 342 . 344 . 346 . 348 . 350 and the actual initiation trigger points 352 . 364 . 376 . 388 . 356 . 368 . 380 . 392 . 360 . 372 . 384 . 395 through the vision system controller 124 either automatically or by manual input via the user interface 128 be varied when a user the resulting composite images 397 . 398 . 399 , ..., N considered to different characteristics in the welding region 109 to see or optimal settings for the desired picture quality for the features too find the user in the composite pictures 397 . 398 . 399 , ..., N wants to consider.

An exemplary constant exposure technique 400 with a variable exposure initiation delay is in 4 for the sake of simplicity, and for comparison also with a sinusoidal energy waveform 402 similar to the sinusoidal energy waveforms 202 and 302 in the examples of 2 and 3 , The constant exposure example 400 from 4 illustrates the capture of raw images, for example the raw images 404 ' . 410 ' . 416 ' . 422 ' . 406 ' . 412 ' . 418 ' . 424 ' . 408 ' . 414 ' . 420 ' . 426 ' , with constant exposure periods, ie where the exposure periods 404 . 410 . 416 . 422 . 406 . 412 . 418 . 424 . 408 . 414 . 420 . 426 for the raw images 404 ' . 410 ' . 416 ' . 422 ' . 406 ' . 412 ' . 418 ' . 424 ' . 408 ' . 414 ' . 420 ' . 426 ' each have the same duration, but at different sections or phases of the power supply waveform 402 , As in 4 illustrates a first exposure period extends 404 over a portion (one phase) of the power supply waveform 402 between the initiation trip point 428 at which the vision system control unit 124 the camera 126 signals the irradiation of the light sensor arrangement in the camera 126 to initiate with light, that of the sweat region 109 is emitted or reflected, and the termination trip point 430 at which the vision system control unit 124 the camera 126 signals to stop the exposure. The vision system controller 124 may use (detect) a threshold, for example the voltage value at the initiation trip point 428 to send an exposure initiation control signal to the camera 126 as disclosed above, to initiate the exposure. Similarly, each of the other exposure periods 410 . 416 . 422 . 406 . 412 . 418 . 424 . 408 . 414 . 420 . 426 at the respective exposure initiation points 440 . 452 . 464 . 432 . 444 . 456 . 468 . 436 . 448 . 460 . 472 by initiating voltage thresholds for use by the vision system controller 124 to generate the exposure initiation control signals to the camera 126 at those exposure initiation points. As the duration of the exposure periods 410 . 416 . 422 . 406 . 412 . 418 . 424 . 408 . 414 . 420 . 426 in this exemplary exposure technique 400 is the same, the vision system control unit 124 set to provide exposure completion control signals to the camera 126 to exactly the same predetermined time period after each of the respective exposure initiation points 428 . 440 . 452 . 464 . 432 . 444 . 456 . 468 . 436 . 448 . 460 . 472 generated. Accordingly, the exposure periods become 404 . 410 . 416 . 422 . 406 . 412 . 418 . 424 . 408 . 414 . 420 . 426 through the vision system controller 124 at the respective completion trigger points 430 . 442 . 454 . 466 . 434 . 446 . 458 . 470 . 438 . 450 . 462 . 474 on the energy waveform 402 completed. Alternatively, the camera 126 itself have a preset function of stopping the exposure in a predetermined exposure period, so that no exposure completion control signal from the vision system control unit 124 to the camera 126 is needed to the exposure periods 404 . 410 . 416 . 422 . 406 . 412 . 418 . 424 . 408 . 414 . 420 . 426 to end. In another alternative, termination threshold voltage values could be detected by the vision system controller 124 used to send the exposure completion control signals to the camera 126 at the completion trigger points 430 . 442 . 454 . 466 . 434 . 446 . 458 . 470 . 438 . 450 . 462 . 474 trigger. In any case, the camera generates 126 each of the raw pictures 404 ' . 410 ' . 416 ' . 422 ' . 406 ' . 412 ' . 418 ' . 424 ' . 408 ' . 414 ' . 420 ' . 426 ' with the same time duration for each of the respective exposure periods 404 . 410 . 416 . 422 . 406 . 412 . 418 . 424 . 408 . 414 . 420 . 426 , Because, however, some of these particular exposure periods 404 . 410 . 416 . 422 . 406 . 412 . 418 . 424 . 408 . 414 . 420 . 426 at different threshold voltages on the energy waveform 402 are initiated, they take place over different sections (phases) of the energy waveform 402 , This exemplary exposure technique 400 is with the initiation trigger points 428 . 432 . 436 at a first initiation voltage threshold, with the initiation trigger points 440 . 444 . 448 at a second initiation voltage threshold, with the initiation trigger points 452 . 456 . 460 at a third initiation voltage threshold and with initiation trigger points 464 . 468 . 472 at a fourth initiation voltage threshold. Consequently, the raw images 404 ' . 406 ' . 408 ' the same exposure time over the same first section (the same first phase) of the energy waveform 402 , the raw images 410 ' . 412 ' . 414 ' have the same exposure time over the same second section (the same second phase) of the energy waveform 402 , the raw images 416 ' . 418 ' . 420 ' have the same exposure time over the same third section (the same third phase) of the energy waveform 402 , the raw images 422 ' . 424 ' . 426 ' have the same exposure time over the same fourth section (the same fourth phase) of the energy waveform 402 , and those first, second, third and fourth portions (phases) of the energy waveform 402 are different from each other. As a result, over-exposure of light sensors in the light sensor assembly can be counteracted by setting a specific, fixed exposure time and triggering the exposure when the desired light intensity is generated by the weld because of higher voltages in the energy waveform 402 lighter arcs 107 and plasmas 108 generate and lower voltages in the energy waveform 402 darker arc 107 and plasmas 108 produce.

As mentioned above, the intensities of light energy vary from that of the weld region 109 is radiated or reflected, and even physical properties of the welding region 109 , such as melting, droplets, plasma size, spatter, etc., depending on the electrical characteristics of the welding current waveform. That is why the light intensities, features and properties of the weld region 109 that through the raw images 404 ' . 406 ' . 408 ' during this first section (of this first phase) of the energy waveform 402 In some aspects, they are different from the light intensities, features and properties created by the raw images 410 ' . 412 ' . 414 ' during the second section (the second phase) of the energy waveform 402 even if the duration of their exposure periods 404 . 406 . 408 . 410 . 412 . 414 each is the same. Likewise, the light intensities, features and properties of the weld region 109 which are picked up by the other raw images during exposure periods that span other sections (phases) of the energy waveform 402 extend, in some aspects different.

Similar to the explanations given above for the techniques 200 and 300 in the 2 and 3 become the raw images 404 ' . 410 ' . 416 ' . 422 ' during the respective exposure periods 404 . 410 . 416 . 422 are merged to produce the first composite image. Similarly, the raw images 406 ' . 412 ' . 418 ' . 424 ' during the respective exposure periods 406 . 412 . 418 . 424 to be obtained, fused to the second composite image 478 to generate, and the raw images 408 ' . 414 ' . 420 ' . 426 ' during the respective exposure periods 408 . 414 . 420 . 426 are merged to the third composite image 480 to create. These processes can be repeated indefinitely to obtain additional raw images, by which points n 'are represented, to produce additional composite images represented by the points N as long as a user desires. As also explained above, the aperture of the camera 126 , the sensitivity of the light sensors in the light sensor arrangement of the camera 126 and the amount of darkening of the optional dimming disc 130 All of them can be varied, either individually or in any combination, to reach light levels where at least some of the different pixels are passing through the camera 126 generated raw images are neither overexposed nor underexposed.

As explained above, one of the goals of generating the composite images, such as the composite images, is 253 . 255 . 257 the example of 2 , the composite images 397 . 398 . 399 the example of 3 and the composite pictures 476 . 478 . 480 the example of 4 that the welding region 109 ( 1 ) and special features in the welding zone 109 , for example the welding bead 103 , the welding nozzle 104 , the electrode 106 , the arc of light 107 , the plasma 108 , The puddle 111 , the workpieces 110 . 112 and the droplets 121 , can be imaged with high resolution. In this way, the composite images show all the different sections of the weld region 109 and provide valuable information regarding the quality of the weld bead 103 , With such information, adjustments to the parameters of the welding process can be made to ensure a high quality weld. For example, the electric current should be in the sections of the workpieces 110 . 112 next to the electrode 107 lie, generate enough heat to form a melting zone 113 made of molten metal; the droplets 121 should be from the distal end of the electrode 107 melt off in a uniform manner and in the sweat puddle 111 be deposited with minimal welding spatter at most; the sweat puddles 121 should be sufficiently fluid, and their temperature should be high enough to match the melting zone 113 in the workpieces 110 . 112 at the intersection of the workpieces 110 . 112 to merge; and the resulting weld bead 103 should be smooth and even with no visible pores. In addition, the position of the welding tip (in the nozzle 104 not visible) and accordingly the electrode 106 be correct, and the droplets 121 should be at or near the intersection of the workpieces 110 . 112 which are joined, dropped or separated by the weld. By offering the opportunity, the welds 110 . 112 that are usually in the welding area 109 darker, as well as the much brighter plasma, the droplets 121 , The puddle 111 and other features together in one picture, the weld bead can 103 precise and with high quality at the intersection of the weld pieces 110 . 112 be formed. By adjusting the sensitivity of the detectors in the camera 126 , the aperture and / or use of the dynamic dimming disc 130 For example, at least some of the raw images may be obtained with a sufficient amount of light to produce images without overexposure. Of course you can also use lamps 134 ( 1 ) on the camera 126 or any other convenient position to provide additional illumination for background and darker features in the weld region 109 , such as the workpieces 110 . 112 or the welding bead 103 to obtain, because additional light can be added to a reasonable amount of light to the background area, such as the weld pieces 110 . 112 to map. These goals and principles also apply to composite images created by other techniques which will be discussed in more detail below.

An exemplary variable exposure technique 500 is in 5 illustrated with a variable initiation trip delay. For the sake of simplicity, and for comparison, is the energy waveform 502 in 5 illustrated sinusoidally, similar to the energy waveforms 202 . 302 . 402 in the examples of 2 . 3 and 4 , The exemplary technique 500 in 5 is similar to the example technique 400 from 4 insofar, as raw images 504 ' . 510 ' . 516 ' . 522 ' . 506 ' . 512 ' . 518 ' . 524 ' . 508 ' . 514 ' . 520 ' . 526 ' , ..., n ', like the raw pictures 404 ' . 410 ' . 416 ' . 422 ' . 406 ' . 412 ' . 418 ' . 424 ' . 408 ' . 414 ' . 420 ' . 426 ' , ..., n ', during various sections (phases) of the power supply waveform 502 to be obtained. However, the exposure periods have 504 . 510 . 516 . 522 . 506 . 512 . 518 . 524 . 508 . 514 . 520 . 526 each a different duration during the duration of the exposure periods 404 . 410 . 416 . 422 . 406 . 412 . 418 . 424 . 408 . 414 . 420 . 426 always the same. In the exemplary technique 500 have the first four exposure periods 504 . 510 . 516 . 522 a different duration, ie the exposure period 516 is longer than the exposure period 510 which is longer than the exposure period 504 which is longer than the exposure period 522 , Likewise, the exposure periods have 506 . 508 the same duration as the exposure period 504 , the exposure periods 512 . 514 have the same duration as the exposure period 510 , the exposure periods 518 . 520 have the same duration as the exposure period 516 , and the exposure periods 524 . 526 have the same duration as the exposure period 522 , As with the other exemplary exposure techniques 200 . 300 . 400 in the 2 . 3 and 4 can be the initiation trigger points 528 . 546 . 552 . 564 . 532 . 544 . 556 . 568 . 536 . 548 . 550 . 572 and the termination trigger points 530 . 542 . 554 . 566 . 534 . 546 . 558 . 570 . 538 . 550 . 562 . 574 either by timing or by detecting threshold voltages or other electrical properties of the energy waveform 502 be determined. As also above for the exemplary techniques 200 . 300 . 400 in the 2 . 3 and 4 explains, the raw images of the exposure periods 504 ' . 510 ' . 516 ' . 522 ' through the camera 126 during the respective exposure periods 504 . 510 . 516 . 522 were merged to the first composite image 576 to create; the raw pictures 506 ' . 512 ' . 518 ' . 524 ' through the camera 126 during the respective exposure periods 506 . 512 . 518 . 524 are merged to form the second composite image 578 to create; and the raw pictures 508 ' . 514 ' . 520 ' . 526 ' through the camera 126 during the respective exposure periods 508 . 514 . 520 . 526 are merged to form the third composite image 578 to create. The composite pictures 253 . 255 . 257 in the example 200 from 2 , the composite pictures 397 . 398 . 399 in the example 300 from 3 , the composite pictures 476 . 478 . 480 in the example 400 from 4 and the composite pictures 576 . 578 . 580 in the example 500 from 5 can be formed with any desired process for combining the respective raw images. For example, each individual pixel from each individual raw image can be statistically evaluated according to how close each individual pixel is to overexposure or complete underexposure. Other techniques may also be used, such as selecting pixels having a predetermined position in the raw image for use in the composite image based on the particular exposure used. For example, pixels from the center of the detector array may be selected for an initial exposure if that exposure period is very short, and may be selected from peripheral areas of the detector array during long exposures so that the background areas may be viewed. Many other techniques for the image combining process can be used.

In another example implementation of the example techniques 2, 3, 4, and 5 described above, the exposure initiation control signals and the exposure completion control signals may be detected by the welding power supply as described above 122 to the camera 126 as transmitted through the alternative camera control connection 148 in 1 is indicated instead of by a separate vision system control unit 124 , Features and capabilities similar to those of the vision system controller 124 for transmitting such signals to the camera may be in the welding power supply 122 to get integrated. In another implementation, the vision system controller may receive signals from the welding power supply 122 receive and respond to such signals to the camera to the exposure initiation control signals and the exposure completion control signals 126 to generate. Therefore, the vision system control unit 124 an integral part of the welding power supply 122 be.

In one embodiment, which may be used with the example techniques disclosed in U.S. Pat 2 . 3 . 4 and 5 can show the frequency of the energy waveform, for example, the energy waveform 202 in 2 , for example, be set to 110 Hz. Of course, any desired frequency for the power supply waveform 202 which provides exposure times suitable for a particular application, and 110 Hz are mentioned here only as an example. In this example of 2 becomes each of the combined composite images 253 . 255 . 257 at about a quarter of the frequency of the power supply waveform 202 which corresponds to a rate of about 27 frames per second. Standard video has about 30 frames (frames) per second, Blu-ray has 24 frames per second, and movies have about 25 frames per second. Thus, quite a decent video can be made using a power supply waveform 202 which in this example has a frequency of approximately 110 Hz.

6A is a flowchart 600 , which is an exemplary operation of the weld vision and control system 100 for generating images of welds, such as the composite images used in the examples set forth above 2 . 3 . 4 and 5 be generated. At step 602 receives the control unit 124 of the welding vision and control system 100 Operating parameters for the operation of the welding vision and control system 100 , The vision system controller 124 can read these operating parameters from a memory. In a computer system, this memory may be RAM or disk storage or other memory, such as EEPROM or similar memory for hardware implementations. The user interface 128 can also be used to convey these operating parameters. In one embodiment, the vision system controller 124 include a general-purpose computer that can store a number of different operating parameters, such as the weld vision and control system 100 allow to work in different modes to create different images. For example, various modes of operation or techniques are in the 2 - 5 illustrated. In this context, the exemplary techniques 200 . 300 . 400 . 500 in the 2 . 3 . 4 and 5 also referred to as operating modes. Of course, other modes of operation can also be selected. In other embodiments, there may be only one or two modes of operation, and the systems may be provided in advance with the operating data. For example, in the in 10 illustrated embodiment of the manual welding vision system 1000 the operating parameters of the system in hardware, such as EEPROM or similar memory, are loaded and retrieved by a processor to obtain the data and the weld vision system 1000 according to the various embodiments or techniques disclosed herein. For example, in the embodiment of the manual weld vision system 1000 from 10 the vision system controller 124 from 1 in a simple, small electronics package 1008 be encapsulated on a hood 1002 or mounted at another convenient position. The electronics package 1008 contains EEPROM memory or other similar memory containing operating parameters, a microprocessor, a state machine and various electronics. Additionally or alternatively, field programmable gate arrays (FPGAs) and other logic circuits may be included in the small electronics package 1008 which can provide only a single or possibly two different modes of operation.

We stay with you 6A , After the operating parameters for the operation of the welding vision and control system 100 received, the process moves to step 604 to select a set of operating parameters from several different operating modes. Again, if only a single mode of operation is used, such as in the embodiment of the manual weld vision system 1000 in 10 , Step 604 be omitted. The process then applies, at step 606 , the operating parameters to the system, including the camera 126 , to operate. The operation of the camera 126 including setting the various exposure times, aperture, sensitivity, and optional dynamic dimming disc 130 , as well as the logic associated with generating the composite images, is performed by the vision system controller 124 executed. At step 608 become raw images of the welding region 109 through the camera 126 generated. These raw images are synchronized with the welding process by synchronizing the recording of the raw images with the power supply waveform in the manner described above. In other words, the raw images are taken by the camera 126 generated in response to the energy waveform in the manner described above. As a result, successive raw images are synchronized with the energy waveform to produce streams of raw images that are synchronized with the chronological events of the welding process in optimized form to produce specific features in the weld region 109 absorb quickly enough to allow the formation of a stream of composite images, all or certain features in the weld region 109 in real time during the welding process. Accordingly, the images do not jump back and forth, but provide a consistently stable view of each feature as it develops in a chronological sequence of events during the welding process.

We stay with you 6A , At step 610 For example, the composite images are combined to essentially produce a real-time video of the welding process. In this regard, the composite images are simply combined with the rate at which they were generated according to any desired method of the images to produce the desired composite images to produce a real-time video of the welding process. An example of a hardware implementation for combining raw images into the composite images is in FIG 9 and is explained below. Depending on the frame rate, either hardware or software implementations can be used to combine the raw images. At step 612 the composite images are displayed as a video. The composite images may also be analyzed, either automatically or by a viewer, to determine whether welding parameters should be changed. For example, the composite images may be viewed to determine whether the position of the welding tip and the electrode should be modified or whether the voltage or current of the energy waveform or the speed of the welding tip should be changed. Other parameters can be modified.

Like also in 6A The video may be viewed and / or analyzed by an automated system such as, for example, a machine vision system with or without a form of texture recognition, depending on which aspects of the weld or welding process are used for such analysis. Machine imaging and texture recognition techniques are well developed and available on the open market, such as structure recognition libraries for the MATLAB ^™ software platform. For example, the shape and size of the weld bead 103 ( 1 ) itself a lot of information about the quality of the weld. The formation of welding droplets 121 and the development of welding puddles 111 During the welding process, using machine imaging or pattern recognition techniques, it is possible to observe and analyze the current or voltage through the welding power supply 122 to modify the generated energy waveform. Size and position of the droplets formed in the welding process 121 and the deposition of these droplets 121 In the welding process, information may be provided regarding the modification of the position and spacing of the welding tip with respect to the workpieces 110 . 112 deliver. The picture of the welding electrode 106 with respect to the workpieces 110 . 112 also allows modification of the position of the welding tip and the electrode 106 in an automated way. In this regard, the distance of the welding tip and the electrode 106 from the workpieces 110 . 112 or the sweat puddle 111 also be observed and modified in an automated manner. In oscillation wire arc welding, the wire electrode becomes 106 oscillates, causing them to swell upwards from the sweat puddle 111 Moves away while the droplet 121 at the distal end of the wire electrode 106 forms, and then moves down to the droplet formed 121 clean in the puddle 111 so that machine imaging and pattern recognition could be used to monitor this process and automatically determine the energy waveform parameters and the oscillation parameters of the wire electrode 106 to adjust to ensure that the droplets are fully formed and separated from the wire electrode 106 just directly into the puddle 111 separate into it and not over the puddle 111 peel off. As another example, structure recognition software may be configured to emit light around the weld puddle 111 around to detect the melting zone 113 the weld pieces 110 . 112 shows which the puddle 111 surrounds. These melting zones 113 would appear as a curved, light-emitting area, located directly on the edge of the puddle 111 located. Again, the presence of this light emission and the intensity of the radiation can be used for the quality of the weld 103 to determine. Also the height and width of the welding bead 103 can be determined using machine imaging techniques to determine the quality of the weld and make adjustments to the welding process, such as modifications of the current or modifications to the speed or position of the welding head to achieve the desired size and shape, uniformity, etc. the welding bead 103 to obtain. Such machine imaging and structure recognition functions may be performed by the vision system controller 124 equipped with corresponding machine imaging and structure recognition applications and parameters to which composite images are applied. When the vision system controller 124 , which applies such machine-imaging and pattern-recognition processes to the composite images, identifies a condition or feature in the welding process that requires adjustment, so gives the vision system controller 124 Signals to the welding power supply 122 or to the robot system controller 142 or both to modify the parameters or conditions that need to be modified. For example, waveform control signals from the vision system controller 124 to the welding power supply the welding power supply 122 induce electrical parameters of the power supply waveform 136 such as voltage, current, frequency, modulation, shape (rise, peak, background and fading slopes, amplitudes, etc.), impedance or other characteristics to be adjusted or modified. Position control signals from the vision system controller 124 to the robot system control unit 142 can the robot system control unit 142 cause signals to be output to the robot system actuators about the welding nozzle 104 , the tip in the nozzle and the electrode 106 in any direction and in any orientation or aspect with respect to the weldments 110 . 112 for example, by appropriate mechanical linkage 146 depending on the type of welding work and the type of workpieces to move for a given welding job. Such robotic welding systems with different actuators 144 and poles 146 and robotic system controllers with control software and firmware are well known and available on the open market. Alternatively, the software of the robot control unit may also be in the vision system control unit 124 be implemented. Other parameters of the welding process can also be automatically analyzed and adjusted by applying machine imaging and pattern recognition processes to the composite images. Alternatively, the vision system controller 124 in a simpler implementation, an alarm or notification by the display device 138 or another separate alarm or notification system (not shown) when the machine imaging and pattern recognition processes applied to the composite images identify a condition or feature in the welding process that requires adjustment.

The process of 6A then walk to step 614 Ahead. At this point, it is determined if another mode of operation should be used for the imaging system. Another mode, such as the technique 200 . 300 . 400 or 500 , in the 2 . 3 . 4 or 5 or any other technique, may be selected by a user, or this process may be determined in an automated manner. For example, a first mode of operation may not have enough definition or useful information about the darker features in the weld region 109 ( 1 ), such as the welding bead 103 or the workpieces 110 . 112 , This determination may be made simply by looking at the composite images or a video made with the composite images, or it may be automatically hit by machine imaging, measuring the light value of the pixels along the periphery of the composite images, or through another automated process. Another mode of operation of the weld vision and control system may provide better illumination or light detection from those darker regions having longer exposure periods or exposure periods extending over multiple portions (phases) of the energy waveform, as discussed above. In another example, over-exposure of the image may occur in areas around the welding tip, such as at the electrode 106 or in the plasma 108 , no clear picture of those features or droplets 121 located at the distal end of the electrode 106 form or in the sweat puddle 111 be deposited. In this case, another mode of operation may be selected which better captures raw images of those features for use in generating the composite images. Again, various exemplary modes of operation through the techniques in the 2 - 5 illustrated. These modes may be in the vision system controller 124 default so that the vision system controller automatically uses the parameters set for those modes, or data can be sent via the user interface 128 entered to modify the operating modes. If it is determined that another operating mode for the weld vision and control system 100 should be used, so the process returns 6A to step 604 back where a set of operating parameters is selected from several different modes or a mode simply into the user interface 128 is entered. In this regard, the user interface 128 preset modes in the weld vision and control system 100 save and apply.

If at step 614 of in 6A If it is determined that no other mode is to be used, the process moves to step 616 proceeding, where it is determined whether the weld is satisfactory. If the weld is satisfactory, the process returns to step 612 back so that the video can still be viewed and analyzed. If at step 616 is determined that the weld is not satisfactory, the process moves to step 618 proceeding where the welding system parameters are modified. The process then returns to step 608 back, in which the composite images of the adjusted welding process are generated.

6B is a flowchart 650 , illustrating an exemplary operation of the vision system controller 124 illustrated. In the 6B Illustrated steps may be performed by a computer system, an embedded processor, or logic hardware, such as Field Programmable Gate Arrays (FPGAs). As in 6B discloses the vision system controller reads 124 the thresholds at step 652 for the power supply waveform. The vision system controller 124 then reads at step 654 any delays associated with one or more exposures, as in the 2 - 5 disclosed. At step 656 the control unit reads the exposure periods. All of this data can be stored in RAM or ROM memory or in a hardware implementation in EEPROMs or other memory. If the exposure periods are not expressed in clock pulses, so can the vision system controller 124 the number of clock pulses for each exposure at step 658 to calculate. At step 660 reads the vision system controller 124 the detector sensitivity data. As disclosed above, the detectors of the light sensor array in the camera 126 have an adjustable sensitivity. The sensitivity of these detectors in the camera 126 can be adjusted so that they more or less sensitive to the light that falls on the light sensor assembly. Sensitivity data can be stored for each of the exposure periods as in the 2 - 5 so that the sensitivity can be changed for each of the exposure periods. Alternatively, a single sensitivity can be selected for all exposure periods. At step 662 reads the vision system controller 124 the aperture data. The aperture data may be changed for each of the exposure periods to adjust the amount of light that is incident on the light sensor assembly of the camera 126 meets. At step 664 generates the vision system control unit 124 an exposure initiation control signal to the camera 126 to irradiate the light sensor array with light energy from the welding region 109 emitted or reflected, initiate. The exposure initiation control signal for initiating the exposure may be generated in response to the welding current waveform reaching a threshold, or in response to a delay from the time the energy waveform reaches a threshold, as discussed above. At step 668 The vision system controller generates an exposure completion control signal to the camera 126 for stopping the irradiation of the light sensor array with light energy coming from the welding region 109 is emitted or reflected when the number of clock pulses for each exposure period is reached. Alternatively, an exposure termination threshold may be used to trigger generation of the exposure completion control signal to the camera 126 , At step 670 Control signals are generated to provide sensitivity and aperture as dictated by the vision system controller 126 read sensitivity data and aperture data. Again, the control signals can be generated for each exposure period. At step 672 be the control signals to the camera 126 applied. The camera 126 then adjusts all parameters according to the control signals. At step 674 be the image data from the camera 126 for each of the raw images generated during each exposure period by the vision system controller 124 receive. At step 676 combines the vision system controller 126 the individual images into composite images using various logic functions. Again, these logic functions may be any desired logic functions for combining the pixels of each of the individual raw images in each set of images to obtain the desired composite images. At step 678 the composite images are displayed for viewing.

7 illustrates an exemplary system 700 for initiating irradiation of the light sensor arrangement of the camera 126 with the light energy coming from the sweat region 109 is emitted or reflected. As in 7 illustrates, the energy waveform 704 as well as a threshold 706 into a comparator 702 fed. The comparator 702 compares the magnitude of an electrical property of the energy waveform 704 , such as the voltage, with the threshold 706 , If these values match, the comparator generates 702 an exposure initiation trigger signal 708 , The exposure initiation trigger signal is then placed in a delay counter 710 , The delay counter counts a number of possibly existing clock pulses 712 until the delay value 720 is reached. The delay counter 710 then generates a trigger 714 , The trigger 714 is in the control signal generator 716 fed, which is a control signal 718 generated in the camera 126 is fed. Of course that can be in 7 illustrated system even without the delay counter 710 work. The delay counter 710 offers more flexibility, especially if the delay value 720 can be modified. The modified delay value 720 can be used in different operating modes of the welding vision and control system 100 be used.

In the exemplary operating modes (techniques) included in the 2 . 3 . 4 and 5 are illustrated, sets of four consecutive raw images are combined in one way or the other into composite images. For example, as described above, the first four raw images 204 ' . 210 ' . 216 ' . 222 ' combined to the first composite picture 253 to create. The combining process is repeated to combine subsequent raw images into composite images. Although in the examples of 2 . 3 . 4 and 5 If there are four raw images to be combined to produce a composite image, any number of raw images may be used to create a composite image. Electronic values generated by individual sensors of two-dimensional sensor arrays are generated as a raster of pixel light intensity values of the image and are usually read out of the light sensor array in a raster scan, such as a series of individual pixel data read out of the raster line by line , usually with the pixel value in a given corner of the grid starting and progressing line by line to the last pixel value in the opposite corner of the grid. An exemplary system that can be used to temporally align corresponding pixels from the four raw images for combination in a composite image is schematically illustrated in FIG 8th shown. As in 8th shown are three shift registers 810 . 812 and 814 used to calculate the corresponding pixel values in the respective pixel streams 802 . 804 . 806 from the first, second and third raw images, a set of four raw images used to produce a composite image (for example, the raw images 204 ' . 210 ' . 216 ' that are used for the composite image 253 in 2 to generate) temporally on the pixel stream 808 of the fourth raw image used to generate the composite image (for example, the raw image 222 ' also for creating the composite image 253 in 2 is used), to align. Practically, the respective pixel streams of each of the first three raw images (for example, the raw images 204 ' . 210 ' . 216 ' ) progressively through the respective shift registers 810 . 812 . 814 so delayed that they temporally affect the pixel stream of the fourth raw image (for example, the raw image 222 ' ) are aligned. When the corresponding pixel values of the four pixel streams for the four raw images are temporally aligned, they may perform an evaluation and selection process for selecting the particular pixel values from the four raw images (eg, raw images 204 ' . 210 ' . 216 ' . 222 ' ) used to make up the composite image (for example, the composite image 253 in 2 ), as explained in more detail below.

As in 2 can be seen, the raw picture is 204 ' completely through the camera 126 at the time of the exposure completion trigger 230 generated while the raw picture 222 ' completely through the camera 126 at the time of the exposure completion trigger 266 is produced. In other words, the exposure becomes for each of these raw images 204 ' . 222 ' at those respective times 230 . 266 completed, and the serial pixel streams for those raw images 204 ' . 222 ' be through the camera 126 at the respective times 230 . 266 Posted. That's why the pixel values for the raw image 204 ' by the amount of time between the exposure completion trigger point 230 and the exposure completion trigger point 266 be delayed. The number of clock pulses becomes between those two exposure completion trigger points 230 . 266 determined, and to a shift register 810 this number of displacement cells is transmitted, so the pixel stream 802 from the first raw picture 204 ' delayed by this amount of time. When the serial pixel stream 802 in the shift register 810 occurs, then conduct the clock pulses 816 the pixel data through the shift register 810 to the exit 820 further.

Likewise, the second pixel stream becomes 804 from the second raw image (for example the raw image 210 ' ) delayed by a predetermined amount. In this example, the delay is equal to the amount of time between the exposure completion trigger point 242 for the second raw picture 210 ' and the exposure completion trigger point 266 for the fourth raw picture 222 ' , The shift register 812 shifts the pixel data stream 804 from the second raw picture 222 ' by the shift register in response to the clock signal 816 , The number of cells in the shift register 812 is equal to the number of clock pulses between the exposure completion trigger point 242 and the exposure completion point 266 , The pixel stream 806 in 8th is formed by the third raw image, such as the raw image 216 ' in 2 , The shift register 814 the serial pixel stream 806 in response to the clock signal 816 shifts. The pixel stream 808 of the fourth raw image is not delayed by a shift register. The pixel streams 802 . 804 . 806 all are temporal to the pixel stream 808 aligned. Consequently, the output signals include 820 . 822 . 824 . 826 temporally aligned output signals 818 , In other words, corresponding pixels for each of the four raw images (for example, the raw images 204 ' . 210 ' . 216 ' . 222 ' in 2 ) in a set of raw pictures forming a single combined picture (for example, the first composite picture 253 in 2 ), all at the exit 818 aligned temporally. In this way, pixel values of corresponding pixels of each of the raw images in each set of raw images may be compared to select a single pixel value from corresponding four pixels to use to generate the combined image. On the alignment device of 8th It may be possible to dispense with a digital computer system implementation because pixels in such systems can be stored with addresses and comparisons can be made based on address locations.

9 FIG. 10 is a schematic illustration of an exemplary embodiment of an image combiner. FIG 900 , The four different pixel streams of the output signals 820 . 822 . 824 . 826 from the 8th all at the exit 818 from 8th are temporally aligned, are in the image combiner 900 in 9 are fed and comprise a first image pixel stream 902 , a second image pixel stream 904 , a third image pixel stream 906 or a fourth image pixel stream 908 , Accordingly, each of the individual raw images (for example, the raw images 204 ' . 210 ' . 216 ' . 222 ' in 2 ) a set of four raw images that are used to create a composite image (for example, the first composite image 252 in 2 ). The composite image can be obtained by selecting pixel values from the pixel streams of the four different raw images using the image combiner 900 be generated. The pixel stream 902 of the first raw image (for example raw image 204 ' ) is in an overexposure comparator 926 and an underexposure comparator 934 fed. Each pixel of the first pixel stream 902 has a digital value that indicates the brightness or intensity of the incident radiation that illuminates this pixel of the raw image. This digital value comes with an overexposure value 910 compared to a delta signal 942 to generate that difference between the overexposure value 910 and the brightness or intensity of the light energy of the weld region 109 ( 1 ), which was incident on this pixel, as the light sensor arrangement of the camera 126 was irradiated with the light energy from the welding region 109 was radiated or reflected. This difference signal 942 becomes the overexposure difference comparator 958 fed. Each pixel in the pixel stream 902 is also in the underexposure comparator 934 which provides the digital brightness value of each of the pixels in the pixel stream 902 with an underexposure value 918 compares. The underexposure value 918 may simply be zero, or it may represent another value selected by a user. Both the overexposure value 910 as well as the underexposure value 918 can be done by a user through the user interface 128 be entered. Otherwise, these overexposure and underexposure values may be in the overexposure comparator 926 and the under-exposure comparator 934 get saved. The difference signal 950 that the difference between the underexposure value 918 and the intensity of the light energy from the weld region 109 indicating that this pixel was incident as the light sensor arrangement of the camera 126 was irradiated with the light energy from the welding region 109 is radiated or reflected becomes the underexposure difference comparator 962 fed.

Likewise, the second pixel stream becomes 904 of the second raw image in the overexposure comparator 928 and the underexposure comparator 936 fed. Compare the pixel values in this pixel stream 904 be with the overexposure value 912 and the underexposure value 920 adjusted to an overexposure difference signal 944 and an under-exposure difference signal 952 to create. The overexposure difference signal 944 becomes the overexposure difference comparator 958 fed. The underexposure difference signal 952 will be in the underexposure difference comparator 962 fed.

Similarly, the third pixel stream 906 of the third raw image into an overexposure comparator 930 and an underexposure comparator 938 fed. The overexposure comparator 930 generates an overexposure difference signal 946 placed in the overexposure difference comparator 958 is fed. The overexposure difference signal 946 is the difference between the intensity of the incident radiation that is the pixel in the light sensor array in the camera 126 illuminated during the exposure, and the overexposure value 914 , The pixel stream 906 is also in the underexposure comparator 938 fed to the intensity of the incident radiation, which is the pixel in the light sensor array in the camera 126 lit during exposure, and the underexposure value 922 compares to an underexposure difference signal 954 in the underexposure difference comparator 962 is fed.

Similarly, the fourth pixel stream 908 of the fourth raw image in the overexposure comparator 932 and the underexposure comparator 940 fed. The overexposure comparator 932 generates an overexposure difference signal 948 placed in the overexposure difference comparator 958 is fed. The overexposure difference signal 948 is the difference between the intensity of the incident radiation that is the pixel in the light sensor array in the camera 126 illuminated during the exposure, and the overexposure value 916 , The pixel stream 908 is also in the underexposure comparator 940 fed to the intensity of the incident radiation, which is the pixel in the light sensor array in the camera 126 lit during exposure, and the underexposure value 924 compares to an underexposure difference signal 956 in the underexposure difference comparator 962 is fed.

The overexposure values 910 . 912 . 914 . 916 and the underexposure values 918 . 920 . 922 . 924 may be fixed for a particular system, or they may be adjustable either manually or automatically with machine imaging techniques.

In an in 9A Illustrated example is the composite image 253 in 2 from four raw pictures 204 ' . 210 ' . 216 ' . 222 ' fused as explained above. As also explained above, these four raw images 204 ' . 210 ' . 216 ' . 222 ' in 2 through the camera 126 from progressively longer exposure periods 204 . 210 . 216 . 222 generated. That's why the pixel light sensors in the light sensor array in the camera had 126 progressively longer exposure periods 204 . 210 . 216 . 222 in which light has been absorbed, that of certain features in the welding region 109 ( 1 ) is radiated or reflected, such as the weld bead 303 , the welding nozzle 104 , the welding electrode 106 , the arc 107 , the plasma 108 , of the weld puddle 111 , the workpieces 110 . 112 , the melting zone 113 and the droplet 121 , Some of these features (for example, the arc 107 and the plasma 108 ) are slightly lighter than others (for example, the electrode 106 , the sweat puddle 111 , the droplet 121 and the melting zone 113 ) and much brighter than others (for example, the welding bead 103 , the welding nozzle 104 and the workpieces 110 . 112 ). That's why the intense light energy that comes from the brightest features (for example, the arc 107 and the plasma 108 ) is emitted or reflected, a higher probability of overexposure of the relevant light sensors or detectors in the light sensor arrangement of the camera 126 on which such intense light energy is focused, while the less intense light energy of less bright features has a lower probability of the respective light sensors or detectors in the light sensor arrangement of the camera 126 to over-emphasize on which such a less intense light energy is focused. Overexposed light sensors or detectors do not provide usable pixel data for images. So useful pixel data from the light sensors or detectors in the light sensor assembly of the camera 126 In order to obtain the most intense light energy, it is necessary to limit the irradiation of these light sensors or detectors with such intense light energy. In contrast, when light energy, the darker features (for example, the weld bead 103 and the workpieces 110 . 112 ), not enough energy for the light sensors or detectors in the camera 126 , to which such low-energy light is focused, has to generate usable pixel data from these darker features, these pixels in the resulting raw images do not recognize these darker features. Therefore, longer exposure periods may allow enough light energy from these darker features to pass through the light sensors or detectors in the camera's light sensor array 126 , upon which such less intense light energy is focused, is detected, thereby allowing these light sensors or detectors to produce useful pixel data for these darker features. That is why it is a goal of the progressively longer exposure periods 204 . 210 . 216 . 222 in the example of 2 to enable the respective light sensors or detectors in the light sensor arrangement of the camera 126 , on which the most intense light energy of the brightest features is focused, usable pixel data without overexposure during the shorter exposure periods (for example, during the first and second exposure periods 204 . 210 ) even when the light sensors or detectors on which the less intense light energy is focused can not produce usable pixel data during these shorter exposure periods. Then, the light sensors or detectors in the light sensor arrangement of the camera 126 on which the less intense light energy is focused by the darker features during the subsequent, longer exposure periods (for example, during the third and fourth exposure periods 216 . 222 ) generate usable pixel data even if the light sensors or detectors on which the most intense light energy is focused may be overexposed. So if parameters (for example aperture, sensor sensitivity and optional attenuation with the optional dimming disc 130 ( 1 )) [...], so has the first raw picture 204 from the shortest exposure period 204 in the example of 2 usable pixels of the brightest features (for example, the arc 107 and the plasma 108 ), while each subsequent subsequent raw image 210 ' . 216 ' . 222 ' in the example of 2 can have more pixels from overexposed light sensors or detectors, which are thus useless, but also more usable pixels from light sensors or detectors for the darker features (eg, the weld bead 103 and the workpieces 110 . 112 ). The light energy of medium intensity of more or less bright features (for example, the nozzle 104 , the electrode 106 , the puddle 111 , the melting zone 113 and the droplet 121 ) may be in an area that makes it the light sensors or detectors in the light sensor array of the camera 126 on which such medium energy light energy is focused allows useful pixels in some or all of the raw images 204 ' . 210 ' . 216 ' . 222 ' to create.

The purpose of the image combiner 900 in 9 is it, corresponding pixels of the raw images 204 ' . 210 ' . 216 ' . 222 ' the exemplary techniques 200 from 2 to select and merge to the composite image 253 with pixels that clearly produce one, some or all of the features in the weld region 109 ( 1 ) as a user wishes for a particular view, analysis or control. Of course, this purpose also applies to the other exemplary techniques and raw images described herein. In an exemplary application of the combiner 900 are arbitrary pixel values 980 . 981 . 982 . 983 of any respective corresponding pixels in the raw images 204 ' . 210 ' . 216 ' . 222 ' in 9A graphically as they flow in the first, second, third and fourth image pixels 902 . 904 . 906 . 908 in 9 occur. Higher pixel values in the graph mean that brighter, but no particular units of brightness light energy intensities are used for this illustration. In this example of 9A are the overexposure values 910 . 912 . 914 . 916 for all four overexposure comparators 926 . 928 . 930 . 932 in 9 each set the same, although they could be different. Likewise, the underexposure values are 918 . 920 . 922 . 924 for all four Unterbelichtungskomparatoren 934 . 936 . 938 . 940 in 9 in this example of 9A each set the same, although they could be different. Because the first raw picture 204 ' has the shortest exposure period ( 2 ), is the pixel value 980 of the pixel in this raw image 204 ' probably lower than the progressively higher pixel values 981 . 982 . 983 of the corresponding pixel in the second, third and fourth raw images 210 ' . 216 ' . 222 ' as explained above.

If these pixel values 980 . 981 . 982 . 983 from the raw pictures 204 ' . 210 ' . 216 ' . 222 ' with the overexposure value 910 . 912 . 914 . 916 in the overexposure comparators 926 . 928 . 930 . 932 from 9 are compared, the resulting overexposure difference signals 942 . 944 . 946 . 948 progressively smaller, as in 9A illustrated. In this example, the pixel value is 983 of the fourth raw picture 222 ' due to the long exposure period 222 ( 2 ), during which the fourth raw picture 222 ' as overexposed illustrates what can happen when high-intensity light energy from a very bright feature in the weld region 109 (for example, the arc 107 or the plasma 108 ) on the light sensor or detector in the light sensor arrangement of the camera 126 who generated this pixel was focused. That is why, as in 9A illustrates the resulting overexposure difference signal 948 for this pixel value 983 in the fourth raw picture 222 ' null, indicating that this pixel is in the fourth raw image 222 ' not usable. On the other hand, the overexposure difference signals are not equal to zero 942 . 944 . 946 that from the pixel values 980 . 981 . 982 for the corresponding pixels in the first, second and third raw images, respectively 204 ' . 210 ' . 216 ' result in each of these three pixel values 980 . 981 . 982 potentially for the composite image 253 ( 2 ), depending on which brightness, contrast or other image properties for the resulting composite image 253 are desired.

We stay with you 9A , If these pixel values 980 . 981 . 982 . 983 from the raw pictures 204 ' . 210 ' . 216 ' . 222 ' with the underexposure value 918 . 920 . 922 . 924 in the under-exposure comparators 934 . 936 . 938 . 940 from 9 are compared, the resulting underexposure difference signals 950 . 952 . 954 . 956 progressively smaller. In this example, the pixel value is 980 from the first raw picture 222 ' due to the short exposure period 204 ( 2 ), during which this first raw picture 222 ' was generated as dark. This can happen when light energy of low intensity comes from a darker feature in the weld region 109 (For example, the weld 103 or the workpieces 110 . 112 ) on the light sensor or detector in the light sensor arrangement of the camera 126 who generated this pixel was focused. That is why, as in 9A illustrates the resulting underexposure difference signal 950 for this pixel value 980 in the first raw picture 204 ' null, indicating that this pixel is in the first raw image 204 ' may not be useable unless the user cares whether the darker features in the weld region in a particular composite image 253 are visible or not. For example, the user or an automated machine vision system may only be at the droplet 121 which is usually not one of the darkest features; In this case, this pixel value could be 980 be usable. On the other hand, the underexposure difference signals are not equal to zero 952 . 954 . 956 that from the pixel values 981 . 982 . 983 for the corresponding pixels in the second, third and fourth raw images, respectively 210 ' . 216 ' . 222 ' result in each of these three pixel values 981 . 982 . 983 potentially for the composite image 253 ( 2 ), depending on which brightness, contrast or other image properties for the resulting composite image 253 are desired.

However, because the corresponding pixel is from the fourth raw image 222 ' due to overexposure, as explained above, and because the corresponding pixel from the first raw image 204 ' is underexposed, as explained above, in this example only the corresponding pixel values 981 . 982 from the second and third raw images 210 ' . 216 ' usable to illuminate a feature of the welding region 109 ( 1 ) in a composite picture 253 to show. Of course, other exposure periods over other portions (phases) of the energy waveform, other light sensor placement sensitivity settings, other aperture settings, other light attenuation, auxiliary illumination, and other adjustments may yield different results for other pixels. It is possible that most or even all corresponding pixel values of the raw images may be kept below overexposure and above underexposure by parameters such as exposure periods, energy waveform phases over which the exposures are made, sensor placement sensitivity settings, iris settings, light attenuations, auxiliary illuminations, and other adjustments be varied dynamically during the exposure periods.

Like also in 9 Shown are bright area values 960 in the overexposure difference comparator 958 fed. Similarly, dark area values become 964 in the underexposure difference comparator 962 fed. The overexposure difference signals 942 . 944 . 946 . 948 are also included in the overexposure difference comparator 958 fed. The overexposure difference comparator 958 compares the overexposure difference signals 942 - 948 , and choose in one Embodiment, the largest overexposure difference signal in the scope of the range values 960 falls. The selected overexposure-cleaned pixel 966 at the output of the overexposure difference comparator 958 therefore has a pixel value furthest from the overexposure value, but still in the bright range of the values 960 falls. Accordingly, the pixel selected from the four different pixel streams is a pixel that is not overexposed but has a pixel value that can be displayed and viewed in the composite image. In the above discussed example of 9A can the bright area values 960 be set so that they have a bright area 960 form as he is in 9B is illustrated. This example becomes the pixel value 980 from the first raw picture 204 ' as below the Hell area 960 ' lying rejected, and the pixel value 983 from the fourth raw picture 222 ' is considered over the Hell area 960 ' lying rejected. Between the two pixel values 981 . 982 from the respective second and third raw images 210 ' . 216 ' has the pixel from the second raw image 210 ' an overexposure difference signal 944 which is larger than the overexposure difference signal 946 of the pixel from the third raw image 216 ' , That is why the overexposure difference comparator chooses 958 ( 9 ) according to the test explained above, the pixel from the second raw image 210 ' for use in merging the composite image 253 ( 2 ), and this pixel with its pixel value 981 is considered the selected overexposure-corrected pixel 966 to the pixel selector 970 output. In other words, the selected overexposure-corrected pixel 966 is a pixel that can be viewed in the composite image and is not too close to the overexposure point. Of course, the overexposure difference comparator could 958 also be set with another test. For example, instead of selecting the largest overexposure difference signal, which is within the range of bright range values 960 could fall, the overexposure difference comparator 958 be set to select the smallest overexposure difference signal within the range of the range values 960 falls. If the upper end of the bright area values 960 is set sufficiently below the overexposure value to ensure that a near-overexposure condition is not a problem, then this test selects the brightest acceptable pixel used in the example of FIG 9B the pixel from the third raw picture 216 ' is.

The underexposure difference signals 950 . 952 . 954 . 956 be in the underexposure difference comparator 962 fed. The underexposure difference comparator 962 selects the underexposure difference signal, which is the largest, but still in the dark area values 964 falls. In other words, it is desirable to select pixels that are not too dark to be seen in a composite image and still fall within a range of values. The selected underexposure-corrected pixel 968 will then be in the pixel selector 970 fed. In the example of 9A can the dark area values 964 be set to a dark area 964 form as in 9C illustrated. This example becomes the pixel value 980 from the first raw picture 204 ' as below the dark area 964 ' lying rejected, and the pixel value 983 from the fourth raw picture 222 ' is considered above the dark area 964 ' lying rejected. Between the two pixel values 981 . 982 from the respective second and third raw images 210 ' . 216 ' has the pixel from the third raw image 216 ' an overexposure difference signal 954 which is larger than the overexposure difference signal 952 of the pixel from the second raw image 216 ' , Therefore, the underexposure difference comparator selects 962 ( 9 ) according to the test explained above, the pixel from the third raw image 210 ' for use in merging the composite image 253 ( 2 ), and this pixel with its pixel value 982 is chosen as the underexposure-corrected pixel 968 to the pixel selector 970 output. In other words, the selected underexposure-corrected pixel 968 is a pixel that can be viewed in the composite image and is not too close to the underexposure point. Of course, the underexposure difference comparator could 962 also be set with another test. For example, instead of selecting the largest overexposure difference signal, that is, the amount of dark area values 964 could fall, the overexposure difference comparator 962 can also be set to select the smallest underexposure difference signal within the range of the range values 964 falls. If the lower end of the dark area values 964 is set sufficiently above the underexposure value to ensure that the pixel is seen in the composite image, this test selects the darkest acceptable pixel used in the example of FIG 9B the pixel from the second raw image 216 ' is.

The pixel selector 970 selects between the selected overexposure-corrected pixel 966 and the selected underexposure-corrected pixel 968 for a selected preferred pixel 972 , Depending on the bright range values 960 and the dark area values 964 included in the overexposure difference comparator 958 and the underexposure difference comparator 962 As explained above, these pixels may be the same pixel. Furthermore, if it is not a selected overexposure-corrected pixel 966 from the overexposure difference comparator 958 there, the pixel selector will choose 970 the underexposure corrected pixel 968 from the underexposure difference comparator 962 , If it is not selected underexposure-corrected pixel 968 from the underexposure difference comparator 962 there, the pixel selector will choose 970 automatically the overexposure-corrected pixel 966 from the overexposure difference comparator 958 , The selected pixel 972 then becomes an image generator 974 sent, which generates the composite image. However, if it is neither a selected overexposure-cleaned pixel 966 another selected underexposure pixel 968 There, the pixel selector sends 970 no selected pixel 972 to the image generator 974 , If there are a number of pixels not present in the composite image, then other acceptable pixels in the raw images can be generated by adjusting parameters such as exposure periods, phases of the energy waveform over which exposures extend, etc., or by operating the camera 126 such as sensitivity of the light sensor assembly, aperture, optional dimming disc, etc., as discussed above. Furthermore, the range values 960 . 964 adjusted so that they contain more selected pixels.

The pixel selector 970 can apply any of a variety of different criteria that exist between the overexposure-corrected pixel 966 and the underexposure corrected pixel 968 to select a selected pixel 972 to the image generator 974 to send. For example, to the pixel selector 970 a median pixel value may be transmitted, and it may be the overexposure-corrected pixel 966 and the underexposure corrected pixel 968 compare with the median pixel value. The pixel selector 970 may select the pixel having the pixel value which is furthest from the median value, or may select the pixel having the pixel value that is least different from the median value. The former case can provide more contrast for the resulting composite image, and the latter can bring more uniformity into the resulting composite image. In some cases, it also might not matter if the overexposure-corrected pixel 966 or the underexposure adjusted pixel is selected so that random selection or alternate selection between these two pixels can provide a satisfactory result.

The image combiner 900 from 9 is an example of the way pixels can be selected from raw images for a combined image. Other modifications may be made. For example, the under-exposure comparators 934 . 936 . 938 . 940 be omitted, as well as the underexposure difference comparator 962 , The bright area values 960 can be adjusted so that the underexposure comparators are not needed. For high speed imaging applications, the comparators may be hardware comparators so that the image can be provided in near real time. In addition, the comparators of the image combiner 900 Also include software comparators that act as a section of a software-implemented control unit 124 act. The selected pixels 972 are then sent to the image generator 974 sent a composite image for display on the display device 978 and / or for analysis in an analyzer 976 generated. The analyzer 976 can in the visual system control unit 124 ( 1 ) and the display device 978 can as the display device 138 in 1 be implemented on the composite images 140 either in still or video format.

Another exemplary process 1000 for merging a series of raw images to produce composite images, which may allow for a higher display speed and a smoother video image sequence, is disclosed in US Pat 10 illustrated. In this exemplary process 1000 For example, the raw images are not fused intermittently or in sets of four (or any other convenient number) to produce the composite images, as in the examples of Figs 2 . 3 . 4 and 5 is illustrated, but the composite images 1031 . 1032 . 1033 . 1034 . 1035 . 1036 . 1037 . 1038 . 1039 , ..., N in 10 are merged in a continuous serial update process. Accordingly, a new (updated) composite image becomes after the generation of each raw image 1004 ' . 1010 ' . 1016 ' . 1022 ' . 1006 ' . 1012 ' . 1018 ' . 1024 ' . 1008 ' . 1014 ' . 1020 ' . 1026 ' , ..., n 'through the camera 126 ( 1 ), rather than waiting for sets of four raw images to pass through the camera 126 are generated before the next composite image is generated. For example, as in 10 illustrates the first composite image 1031 by merging pixels from the first four raw images 1004 ' . 1010 ' . 1016 ' . 1022 ' generated. The second composite picture 1032 is then using pixels from the fifth raw image 1006 ' and by dropping (ie, not using) pixels from the first raw image 1004 ' generated while using pixels from the second, third and fourth raw images 1010 . 1016 will continue. Similarly, when the sixth raw picture 1012 ' through the camera 126 is generated, the third composite image 1033 using pixels from the new, sixth raw image 1012 ' together with pixels from the third, fourth and fifth raw images 1016 ' . 1022 ' and 1006 ' generated. Likewise, each of the subsequent composite images 1033 . 1034 . 1035 . 1036 . 1037 . 1038 . 1039 , ..., N with the newly generated raw images 1012 ' . 1018 ' . 1024 ' . 1008 ' . 1014 ' . 1020 ' . 1026 ' , ..., n 'together with pixels from the immediately preceding three raw images.

Again, for the sake of simplicity, and for comparison, the energy waveform 1002 in 10 shown as sinusoidal, similar to the energy waveform 200 in 2 Although other AC or DC waveforms may be used. Furthermore, for the sake of simplicity, and for comparison, the exposure periods 1004 . 1010 . 1016 . 1022 . 1006 . 1012 . 1018 . 1024 . 1008 . 1014 . 1020 . 1026 in 10 each the same as the exposure periods 204 . 210 . 216 . 222 . 206 . 212 . 218 . 224 . 208 . 214 . 220 . 226 in 2 , Furthermore, these exposure periods have in 10 the same exposure initiation trigger points and the same exposure completion trigger points as the exposure initiation trigger points and exposure completion trigger points in FIG 2 , and the same techniques can be used to set these trigger points. Therefore, for the sake of simplicity, and to avoid unnecessary textual overload and repetition, the exposure initiation trigger points and the exposure completion trigger points in FIG 10 Not shown. It should suffice to state that the raw images 1004 ' . 1010 ' . 1016 ' . 1022 ' . 1006 ' . 1012 ' . 1018 ' . 1024 ' . 1008 ' . 1014 ' . 1020 ' . 1026 ' in 10 can be generated in the same way as each of the raw images in the examples of 2 . 3 . 4 and 5 ,

The merger process that takes place in the 8th . 9 . 9A . 9B and 9C can be used for the first composite image 1030 to create. For example, as in 11 combined with 8th illustrates the respective pixel streams of the first, second and third raw images 1004 ' . 1010 ' . 1016 ' into the respective first, second and third shift registers 810 . 812 . 814 to delay the first, second and third pixel streams enough to temporally apply them to the pixel stream of the fourth raw image 1022 ' align as explained above. As a result, all four pixel streams of the first, second, third and fourth raw images 1004 ' . 1010 ' . 1016 ' . 1022 ' at 820 . 822 . 824 . 826 at the same time T1 is output, so that corresponding pixels in these four raw images 1004 ' . 1010 ' . 1016 ' . 1022 ' the respective inputs 902 . 904 . 906 . 908 of the image combiner 900 ( 9 ) at the same time. The image combiner 900 then selects pixels from the four pixel streams of the raw images 1004 ' . 1010 ' . 1016 ' . 1022 ' to generate the first composite image 1031 ( 10 ) in the image generator 974 ( 9 ), as explained above.

As explained above, when the fifth raw picture 1006 ' ( 10 ) through the camera 126 ( 1 ), the next (second) composite image 1032 in 10 by updating the previous composite image 1031 with new pixel data from the new raw picture 1006 ' and dropping the pixel data from the first raw image 1004 ' generated. This is what the updated (second) composite image becomes 1031 made up of pixels from the second to fifth raw images 1010 ' . 1016 ' . 1022 ' . 1006 ' are selected. With reference to the 8th and 9 For example, such a continuous serial update process may be performed by shifting the pixel streams from the immediately preceding raw images into shift registers 810 . 812 . 814 the delay hardware 800 following the pixel streams fed from the raw images in front of them. As a result, the pixel stream from the latest raw image is temporally aligned to pixel streams of the three immediately preceding raw images. To illustrate the temporal nature of this exemplary process is the delay hardware 800 with their three shift registers 810 . 812 . 814 in 11 symbolically illustrated, although actually only the one delay hardware 800 is used. As mentioned above, the first composite image becomes 1031 generated by the pixel streams from the first four raw images 1004 ' . 1010 ' . 1016 ' . 1022 ' in the delay hardware 800 to temporally align the respective corresponding pixels from these four raw images. The pixel streams from the first three raw images 1004 ' . 1010 ' . 1016 ' . 1022 ' are in the respective shift registers 810 . 812 . 814 to temporally delay these pixel streams enough to temporally send them to the image combiner for a simultaneous output at a time T1 900 ( 9 ). At the same time, the pixel streams become the second, third and fourth raw images 1010 ' . 1016 ' . 1022 ' each in the first, second and third shift registers 810 . 812 . 814 to delay them by an appropriate amount of time, to temporalize them to the pixel stream from the new fifth raw image 1006 ' align when this new fifth raw picture 1006 ' through the camera 126 ( 1 ) is produced. Accordingly, the output signals 820 . 822 . 824 . 826 the pixel streams of the second, third, fourth and fifth raw images 1010 ' . 1016 ' . 1022 ' . 1006 ' from the delay hardware 800 temporally aligned at time T2. Accordingly, these temporally aligned pixel streams become the second, third, fourth, and fifth raw images 1010 ' . 1016 ' . 1022 ' . 1006 ' in the entrances 902 . 904 . 906 . 908 of the image combiner 900 ( 9 ) for pixel selection and generation of the second composite image 1032 ( 10 ) in the image generator 974 ( 9 ), as described above.

At the same time as the pixel streams of the second, third, fourth and fifth raw images 1010 ' . 1016 ' . 1022 ' . 1006 ' temporal in the delay hardware 800 are aligned, the pixel streams of the third, fourth and fifth raw images 1016 ' . 1022 ' . 1006 ' each in the first, second and third shift registers 810 . 812 . 814 to delay them by a convenient amount of time, to temporalize them to the pixel stream from the new sixth raw image 1012 ' align when this new sixth raw picture 1012 ' through the camera 126 ( 1 ) is produced. Accordingly, the output signals 820 . 822 . 824 . 826 the pixel streams of the third, fourth, fifth and sixth raw images 1016 ' . 1022 ' . 1006 ' . 1012 ' from the delay hardware 800 temporally aligned at time T3. Accordingly, these temporally aligned pixel streams become the third, fourth, fifth and sixth raw images 1016 ' . 1022 ' . 1006 ' . 1012 ' in the entrances 902 . 904 . 906 . 908 of the image combiner 900 ( 9 ) for pixel selection and generation of the third composite image 1033 ( 10 ) in the image generator 974 ( 9 ), as described above.

At the same time as the pixel streams of the third, fourth, fifth and sixth raw images 1016 ' . 1022 ' . 1006 ' . 1012 ' temporal in the delay hardware 800 are aligned, the pixel streams of the fourth, fifth and sixth raw images 1022 ' . 1006 ' . 1012 ' each in the first, second and third shift registers 810 . 812 . 814 to delay them by a convenient amount of time, to temporalize them to the pixel stream from the new seventh raw image 1018 ' align when this new seventh raw picture 1018 through the camera 126 ( 1 ) is produced. Accordingly, the output signals 820 . 822 . 824 . 826 the pixel streams of the fourth, fifth, sixth and seventh raw images 1022 ' . 1006 ' . 1012 ' . 1018 ' from the delay hardware 800 temporally aligned at time T4. Accordingly, these temporally aligned pixel streams become the fourth, fifth, sixth and seventh raw images 1022 ' . 1006 ' . 1012 ' . 1018 ' in the entrances 902 . 904 . 906 . 908 of the image combiner 900 ( 9 ) for pixel selection and generation of the fourth composite image 1034 ( 10 ) in the image generator 974 ( 9 ), as described above.

This continuous serial update process continues indefinitely until it is stopped by the user or automatically. 11 illustrates the temporal alignment process by aligning the pixel stream of the ninth raw image 1008 ' on the pixel streams of the three previous raw images 1012 ' . 1018 ' . 1024 ' for use in generating the sixth composite image 1036 , As mentioned above, in this exemplary merge process of 10 creates a new (updated) composite image after each raw image 1004 ' . 1010 ' . 1016 ' . 1022 ' . 1006 ' . 1012 ' . 1018 ' . 1024 ' . 1008 ' . 1014 ' . 1020 ' . 1026 ' , ..., n 'through the camera 126 ( 1 ), rather than waiting for sets of four raw images to pass through the camera 126 were generated before the next composite image is created. So if the frequency of the energy waveform 1002 is set to the exemplary 110 Hz, as described above with respect to the examples of 2 - 5 was illustrated, so would composite images 1031 - 1039 , ..., N are generated at 110 frames per second, but each frame contains all the image information over one-twenty-seventh of a second, ie, four exposures. That is why this technique of 10 For an energy waveform of the same frequency four times as many composite images per unit of time as the images produced by the techniques of 2 - 5 be generated.

As mentioned above, there are several phenomena that occur in the weld region 109 ( 1 ) occur during a welding process, a function of the power supply waveform and can be controlled or influenced by it. For example, the DC waveform 1202 in 12A shaped so that they develop the droplets 121 coming from the distal end of the welding electrode 106 be melted, corresponds to and influences. Modern welding power supplies, such as the welding power supply 122 in 1 , can be programmed to produce DC waveforms 136 produce with desired shapes and properties. The special shaped energy waveform 1202 in 12A has a flat phase 1205 at a base current (I) current level between times t ₁ and t ₂ , which provides a baseline amount of electrical current to the arc 107 and the plasma cone 108 provides. The formation of the droplet 121 From molten electrode metal begins during this flat ground phase 1205 as in the first schematic example view 1281 the welding region 109 illustrated. Then at time t _2, a rise phase 1207 began. During the rise phase 1207 the current strength of the welding current is raised to increase the heat in the electrode and the formation of the droplet 121 to accelerate. After reaching a desired peak current level at time t ₃ , the peak current level becomes a peak current phase 1209 maintained until time t ₃ , where the current strength in a decay phase 1211 begins to decrease. The droplet 121 develops completely during the peak current phase 1209 to the point of detachment from the electrode 106 as in the second illustrative example view 1282 the welding region 109 illustrated. Then has itself in the Ausklingphase 1211 the droplet 121 from the electrode 106 separated, as in the third illustrative example view of welding region 109 is illustrated. The droplet 121 then falls on the sweat puddle 111 where it is with molten metal in the melting zone 113 the workpieces 110 . 112 merges. While the welding nozzle 104 moved further (as indicated by the arrow 105 in 1 indicated), the molten metal cools and solidifies to the weld bead 103 , Thus, by initiating exposure initiation control signals and exposure completion control signals, the exposure periods associated with selected ones of these phases 1205 . 1209 . 1211 agree, in the camera 126 ( 1 ), it becomes the welding vision and control system 100 allows to create composite images of these features, such as developmental stages of the droplets 121 as will be explained in more detail below, which may be viewed in real time or stored for later viewing or analysis.

We turn now predominantly 12B to where, for example, four cycles of the shaped DC waveform 1202 are illustrated and first, second, third and fourth raw images 1204 ' . 1210 ' . 1216 ' . 1222 ' through the camera 126 ( 1 ) with progressively longer first, second, third and fourth exposure periods 1204 . 1210 . 1216 . 1222 during each of these four cycles are generated. Of course, in a practical application, many more raw images will be created during much more cycles of the energy waveform 1202 to be obtained. In the example of 12B become the first, second, third and fourth raw images 1204 ' . 1210 ' . 1216 ' . 1222 ' during the respective first, second, third and fourth exposure periods 1204 . 1210 . 1216 . 1222 generated during the flat baseline phase 1205 the energy waveform 1202 occur. Therefore irradiate in this example of 12B these first, second, third and fourth exposure periods 1204 . 1210 . 1216 . 1222 the light sensors or detectors in the light sensor array 1285 the camera 126 with light energy coming from the sweat region 109 is emitted or reflected when the droplets 121 just at the distal end of the welding electrode 106 begins to form, as by the first schematic example view 1281 the welding region 109 in 12A is illustrated, since this phenomenon during this basic current phase 1205 the energy waveform cycle occurs. Further, in this example, the first, second, third and fourth exposure periods 1204 . 1210 . 1216 . 1222 a progressively longer duration, similar to the example discussed above 2 so that each consecutive raw picture 1204 ' . 1210 ' . 1216 ' . 1222 ' with gradually more light energy from the weld region 109 is produced. However, the exposure periods could 1204 . 1210 . 1216 . 1222 each also have the same duration as above for the exemplary technique of 4 has been described.

As with the earlier examples in the 2 . 3 . 4 . 5 and 10 For example, the detection of thresholds in the energy waveform may be used for the exposure periods 1204 . 1210 . 1216 . 1222 initiate, or the welding power supply 122 may alternatively output control signals corresponding to such thresholds in the energy waveform. As also in the examples of 2 . 3 . 4 . 5 . 10 is explained, the vision system control unit 124 ( 1 ) - or alternatively the welding power supply 122 - the exposure periods 1204 . 1210 . 1216 . 1222 either immediately upon detection or occurrence of such thresholds or after a delay from such detection or occurrence. For example, the initiation threshold for the exposure periods 1204 . 1210 . 1216 . 1222 at the initiation current thresholds 1212 . 1213 . 1214 . 1215 where it is detected that the current strength is the base current level of the fundamental current phase 1205 the energy waveform 1202 achieved while the actual initiation trigger points 1217 . 1218 . 1219 . 1220 for these respective exposure periods 1204 . 1210 . 1216 . 1222 through the vision system controller 124 (alternatively by the welding power supply 122 ) are delayed for predetermined periods of time determined to provide the desired phases and exposure periods for particular purposes or effects. The termination trigger points 1225 . 1226 . 1227 . 1228 are also limited to respective time delays from the respective initiation current threshold points 1212 . 1213 . 1214 . 1215 set as desired for specific purposes or effects.

How graphically in 12B illustrated, allows the shortest exposure period 1204 an ideal light energy radiation for light sensors or detectors in a central section 1287 the light sensor arrangement 1285 by the brightest, most intense light energy coming from the sweat region 109 emitted or reflected, such as by the arc 107 and the plasma 108 , That is why the raw picture has 1204 ' that through the light sensor assembly 1285 with this exposure period 1204 a good resolution of these brightest features, such as the arc 107 and the plasma 108 , At the same time this shortest exposure period leaves 1204 not enough light energy from darker sections of the weld region 109 for the light sensors or detectors in the remaining outer sections 1288 to get raw images of features in these darker sections of the weld region 109 to create. That's why the resulting raw picture shows 1204 ' that in the Exposure period 1204 is generated, only the brightest features, such as the arc 107 and the plasma 108 , and the remaining sections of the raw picture 1204 ' include dark pixels 1290 ,

The next, slightly longer exposure period 1210 creates an overexposed central portion 1286 the light sensor arrangement 1285 because the high-intensity light energy that is emitted or reflected by the brightest features, such as the arc 107 and the plasma 108 , the light sensors or detectors of the light sensor arrangement 1285 in this central section 1286 in this slightly longer exposure period 1210 overexposed. At the same time, this offers a slightly longer exposure period 1210 an ideal light energy radiation for light sensors or detectors in a central section 1287 around the overexposed central section 1286 the light sensor arrangement 1285 around, because the light energy coming from the features in the central portion of the weld region 109 such as the sweat puddle 111 , the melting zone 113 and the resulting droplet 121 , is radiated or reflected, is not bright enough to the light sensors or detectors of the light sensor assembly 1285 to overemphasize that light energy is focused on. The darker outer portions of the weld region 109 do not emit or reflect enough light energy than the light sensors or detectors in the outer sections 1288 the light sensor arrangement 1285 Could produce images. That is why the raw picture has 1210 that through the light sensor assembly 1285 in this slightly longer exposure period 1210 a good resolution of these features of medium brightness, such as the sweat puddle 111 , the melting zone 113 and the resulting droplet 121 , At the same time this leaves slightly longer exposure period 1210 not enough light energy from the darker sections of the weld region 109 for the light sensors or detectors in the remaining outer sections 1288 the light sensor arrangement 1285 to get raw images of features in these darker sections of the weld region 109 to create. That's why the resulting raw picture shows 1210 ' that in this slightly longer exposure period 1210 is produced, only the quite bright, but not the brightest, features, such as the sweat puddle 111 , the melting zone 113 the resulting droplet 121 , The pixels of the central section 1291 of the raw picture 1210 ' are overexposed, and the remaining outer sections of the raw image 1210 ' include only dark pixels 1290 ,

The next, moderately longer exposure period 1216 causes an even larger overexposed central portion 1286 the light sensor arrangement 1285 because the light energy, not only by the brightest features, such as the arc 107 and the plasma 108 , radiated or reflected, but also from the slightly darker features, such as the sweat puddle 111 , the melting zone 113 and the resulting droplet 121 , the light sensors or detectors of the light sensor arrangement 1285 in this even larger central section 1286 overexposed. At the same time this moderately longer exposure period offers 1216 an ideal light energy radiation for light sensors or detectors in a central section 1287 around the overexposed central section 1286 the light sensor arrangement 1285 around, because the light energy coming from the features in this central section of the weld region 109 , such as the electrode 106 and the workpieces 110 . 112 is radiated or reflected in an appropriate area, so that the light sensors or detectors of the light sensor array 1285 on which this light energy is focused can produce image pixels of these features. The darker outer portions of the weld region 109 do not emit or reflect enough light energy for the light sensors or detectors in the outer sections 1288 the light sensor arrangement 1285 to create pictures. That is why the raw picture has 1216 that through the light sensor assembly 1285 in this moderately longer exposure period 1216 a good resolution of these features of medium brightness, such as the electrode 106 and the workpieces 110 . 112 , At the same time this moderately longer exposure period 1216 not enough light energy from darker sections of the weld region 109 for the light sensors or detectors in the remaining outer sections 1288 the light sensor arrangement 1285 to get raw images of features in these darker sections of the weld region 109 to create. That's why the resulting raw picture shows 1216 ' that in this moderately longer exposure period 1216 is produced, only the moderately bright features, such as the sweat puddle 111 , the melting zone 113 the resulting droplet 121 , The pixels of the central section 1291 of the raw picture 1216 ' are overexposed, and the remaining outer sections of the raw image 1216 ' include only dark pixels 1290 ,

The next, longest exposure period 1222 causes an even larger overexposed central portion 1286 the light sensor arrangement 1285 because the light energy of all but the darkest features, such as the arc 107 and the plasma 108 , the sweat puddle 111 , the melting zone 113 , the resulting droplets 121 , the electrode 106 and the inner sections of the workpieces 110 . 112 , radiated or reflected, the light sensors or detectors of the light sensor array 1285 in this even larger central section 1286 overexpose. At the same time, this offers the longest Exposure period 1222 an ideal light energy radiation for light sensors or detectors in an outer section 1287 around the overexposed central section 1286 the light sensor arrangement 1285 around, because the light energy coming from the features in this outer section 1287 the welding region 109 , such as the welding nozzle 104 and the outer sections of the workpieces 110 . 112 is radiated or reflected in an appropriate range for the light sensors or detectors of the light sensor array 1285 to which this light energy is focused lies to produce image pixels of these features. The cooled and solidified weld bead 103 , in 12B not to be seen, would be in the raw picture 1222 ' also be seen, if the camera is in a suitable perspective to the weld bead 103 to have in the field of vision. That is why the raw picture has 1222 ' that through the light sensor assembly 1285 in this longest exposure period 1222 a good resolution of these features of medium brightness, such as the welding nozzle 104 , the outer sections of the workpieces 110 . 112 and the welding bead 103 , That's why this shows in this longest exposure period 1222 generated resulting raw image 1222 ' only the darker features, such as the welding nozzle 104 , the outer sections of the workpieces 110 . 112 and the welding bead 103 , The pixels of the central section 1291 of the raw picture 1222 are overexposed.

The raw pictures 1204 ' . 1210 ' . 1216 ' . 1222 ' through the camera 126 during the respective exposure periods 1204 . 1210 . 1216 . 1222 each of which utilizes usable pixels for some but not all of the features in the weld region 109 has, are merged together to form the composite image 1240 to create. As in 12B shown and discussed above, has the composite picture 1240 Pixel, all features in the welding region 109 with the droplet 121 show that is at the distal end of the electrode 106 begins to form because of this phenomenon during the shallow fundamental current phase 1205 the energy waveform 1202 occurs as in 12A shown and discussed above where the exposure periods 1204 . 1210 . 1216 . 1222 are positioned. Any of the composite image generation processes discussed above may be used to enhance the composite image 1240 from the raw pictures 1204 ' . 1210 ' . 1216 ' . 1222 ' to create.

The exemplary exposure periods 1224 . 1230 . 1236 1242 in 12C are the same as the exposure periods 1204 . 1210 . 1216 . 1222 in 12B shown except that the exposure periods 1224 . 1230 . 1236 1242 in 12C to the peak current phase 1209 the energy waveform 1202 are moved where the droplet 121 made of molten metal, located at the distal end of the electrode 106 is fully developed to move away from the electrode 106 to replace, as in 12A is shown and described above. In this example the 12C can the exposure periods 1224 . 1230 . 1236 1242 by detection or other indication that the increasing current level is the threshold current level of the peak current phase 1209 reached, be initiated. Accordingly, the initiation current thresholds are located 1231 . 1232 . 1233 . 1234 for the exposure periods 1224 . 1230 . 1236 1242 at the starting points of the peak current phase 1209 but the actual exposure periods 1224 . 1230 . 1236 1242 are of the initiation current threshold points 1231 . 1232 . 1233 . 1234 to the respective initiation trigger points 1244 . 1245 . 1246 . 1247 time delayed. The termination trigger points 1251 . 1252 . 1253 . 1254 are also limited to respective time delays from the respective initiation current threshold points 1231 . 1232 . 1233 . 1234 set as desired for specific purposes or effects.

How graphically in 12C illustrates offers the shortest exposure period 1224 an ideal light energy radiation for light sensors or detectors in a central section 1287 the light sensor arrangement 1285 by the brightest, most intense light energy coming from the sweat region 109 such as the arc 107 , the plasma 108 and the droplet 121 , emitted or reflected. That is why the raw picture has 1224 ' that through the light sensor assembly 1285 in this exposure period 1224 a good resolution of these brightest features, such as the arc 107 , the plasma 108 and the droplet 121 , At the same time this shortest exposure period leaves 1224 not enough light energy from darker sections of the weld region 109 for the light sensors or detectors in the remaining outer sections 1288 to get raw images of features in these darker sections of the weld region 109 to create. That's why the resulting raw picture shows 1224 ' that in the exposure period 1224 is generated, only the brightest features, such as the arc 107 , the plasma 108 and the droplet 121 , and the remaining sections of the raw picture 1224 ' include dark pixels 1290 ,

The next, slightly longer exposure period 1230 causes an overexposed central portion 1286 the light sensor arrangement 1285 because the high-intensity light energy, the brightest features, such as the arc 107 , the plasma 108 and the droplet 121 , radiated or reflected, the light sensors or detectors of the light sensor array 1285 in this central section 1286 in this slightly longer exposure period 1230 overexposed. At the same time, this offers little longer exposure period 1230 an ideal light energy radiation for light sensors or detectors in a central section 1287 around the overexposed central section 1286 the light sensor arrangement 1285 around, because the light energy coming from the features in the central portion of the weld region 109 such as the sweat puddle 111 and the melting zone 113 , is radiated or reflected, is not bright enough to the light sensors or detectors of the light sensor assembly 1285 to overemphasize that light energy is focused on. The darker outer portions of the weld region 109 do not emit or reflect enough light energy for the light sensors or detectors in the outer sections 1288 the light sensor arrangement 1285 to get in this slightly longer exposure period 1230 To create pictures. That is why the raw picture has 1230 ' that through the light sensor assembly 1285 in this slightly longer exposure period 1230 a good resolution of these features of medium brightness, such as the sweat puddle 111 and the melting zone 113 , At the same time this leaves slightly longer exposure period 1230 not enough light energy from darker sections of the weld region 109 for the light sensors or detectors in the remaining outer sections 1288 the light sensor arrangement 1285 to get raw images of features in these darker sections of the weld region 109 to create. That's why the resulting raw picture shows 1230 that in this slightly longer exposure period 1230 is produced, only the quite bright, but not the brightest, features, such as the sweat puddle 111 and the melting zone 113 , The pixels of the central section 1291 of the raw picture 1230 ' are overexposed, and the remaining outer sections of the raw image 1230 ' include only dark pixels 1290 ,

The next, moderately longer exposure period 1236 causes an even larger overexposed central portion 1286 the light sensor arrangement 1285 because the light energy, not only by the brightest features, such as the arc 107 , the plasma 108 and the droplet 121 but also from the slightly darker features, such as the sweat puddle 111 and the melting zone 113 , radiated or reflected, the light sensors or detectors of the light sensor array 1285 in this even larger central section 1286 overexposed. At the same time this moderately longer exposure period offers 1236 an ideal light energy radiation for light sensors or detectors in a central section 1287 around the overexposed central section 1286 the light sensor arrangement 1285 around, because the light energy coming from the features in this central section of the weld region 109 , such as the electrode 106 and the workpieces 110 . 112 is radiated or reflected in an appropriate range for the light sensors or detectors of the light sensor array 1285 to which this light energy is focused lies to produce image pixels of these features. The darker outer portions of the weld region 109 do not emit or reflect enough light energy for the light sensors or detectors in the outer sections 1288 the light sensor arrangement 1285 to create pictures. That is why the raw picture has 1236 that through the light sensor assembly 1285 in this moderately longer exposure period 1236 a good resolution of these features of medium brightness, such as the electrode 106 and the workpieces 110 . 112 , At the same time this moderately longer exposure period 1236 not enough light energy from darker sections of the weld region 109 for the light sensors or detectors in the remaining outer sections 1288 the light sensor arrangement 1285 to get raw images of features in these darker sections of the weld region 109 to create. That's why the resulting raw picture shows 1236 ' that in this moderately longer exposure period 1236 is produced, only the moderately bright features, such as the sweat puddle 111 and the melting zone 113 , The pixels of the central section 1291 of the raw picture 1236 ' are overexposed, and the remaining outer sections of the raw image 1236 ' include only dark pixels 1290 ,

The next, longest exposure period 1242 causes an even larger overexposed central portion 1286 the light sensor arrangement 1285 because the light energy of all but the darkest features, such as the arc 107 , the plasma 108 , the droplet 121 , the sweat puddle 111 , the melting zone 113 , the electrode 106 and the inner sections of the workpieces 110 . 112 , radiated or reflected, the light sensors or detectors of the light sensor array 1285 in this even larger central section 1286 overexposed. At the same time, this offers the longest exposure period 1242 an ideal light energy radiation for light sensors or detectors in an outer section 1287 around the overexposed central section 1286 the light sensor arrangement 1285 around, because the light energy coming from the features in this outer section 1287 the welding region 109 , such as the welding nozzle 104 and the outer sections of the workpieces 110 . 112 is radiated or reflected in an appropriate range for the light sensors or detectors of the light sensor array 1285 to which this light energy is focused lies to produce image pixels of these features. The cooled and solidified weld bead 103 , in 12C not visible, would also be in the raw picture 1242 ' be seen if the camera is in a suitable perspective to the weld bead 103 to have in the field of vision. That is why the raw picture has 1242 ' that through the Light sensor arrangement 1285 in this longest exposure period 1242 a good resolution of these features of medium brightness, such as the welding nozzle 104 , the outer sections of the workpieces 110 . 112 and the welding bead 103 , That's why the resulting raw picture shows 1242 ' that in this longest exposure period 1242 is produced, only the darker features, such as the welding nozzle 104 , the outer sections of the workpieces 110 . 112 and the welding bead 103 , The pixels of the central section 1291 of the raw picture 1242 ' are overexposed.

The raw pictures 1224 ' . 1230 ' . 1236 ' . 1242 ' through the camera 126 during the respective exposure periods 1224 . 1230 . 1236 1242 are merged together to form the composite image 1240 to create. The composite picture 1260 shows the droplet 121 made of molten metal completely formed at the distal end of the electrode 106 just before detachment from the electrode 106 because of this phenomenon during the peak current phase 1209 the energy waveform 1202 occurs as in 12A shown and explained above, which is the position where the exposure periods 1224 . 1230 . 1236 1242 are located. Any of the composite image generation processes discussed above may be used to enhance the composite image 1260 from the raw pictures 1224 ' . 1230 ' . 1236 ' . 1242 ' to create.

In the 12D shown exemplary exposure periods 1244 . 1250 . 1256 . 1262 are set to go with the decay phase 1211 the energy waveform 1202 coincide while the droplet is growing 121 made of molten metal from the welding electrode 106 from the electrode 106 has separated and in the puddle 111 falls as explained above. How graphically in 12D illustrates offers the shortest exposure period 1244 an ideal light energy radiation for light sensors or detectors in a central section 1287 the light sensor arrangement 1285 by the brightest, most intense light energy coming from the sweat region 109 emitted or reflected, such as the arc 107 , the plasma 108 and the droplet 121 , That is why the raw picture has 1244 ' that through the light sensor assembly 1285 in this exposure period 1244 a good resolution of these brightest features, such as the arc 107 , the plasma 108 and the droplet 121 , At the same time this shortest exposure period leaves 1244 not enough light energy from darker sections of the weld region 109 for the light sensors or detectors in the remaining outer sections 1288 to get raw images of features in these darker sections of the weld region 109 to create. That's why the resulting raw picture shows 1244 ' that in the exposure period 1244 is generated, only the brightest features, such as the arc 107 , the plasma 108 and the droplet 121 , and the remaining sections of the raw picture 1244 include dark pixels 1290 ,

The next, slightly longer exposure period 1250 causes an overexposed central portion 1286 the light sensor arrangement 1285 because of the high-intensity light energy, that of the brightest features, such as the Electric arc 107 , the plasma 108 and the droplet 121 , radiated or reflected, the light sensors or detectors of the light sensor array 1285 in this central section 1286 in this slightly longer exposure period 1250 overexposed. At the same time, this offers a slightly longer exposure period 1250 an ideal light energy radiation for light sensors or detectors in a central section 1287 around the overexposed central section 1286 the light sensor arrangement 1285 around, because the light energy coming from the features in the central portion of the weld region 109 such as the sweat puddle 111 and the melting zone 113 , is radiated or reflected, is not bright enough to the light sensors or detectors of the light sensor assembly 1285 to overemphasize that light energy is focused on. The darker outer portions of the weld region 109 do not emit or reflect enough light energy for the light sensors or detectors in the outer sections 1288 the light sensor arrangement 1285 to get in this slightly longer exposure period 1250 To create pictures. That is why the raw picture has 1250 ' that through the light sensor assembly 1285 in this slightly longer exposure period 1250 a good resolution of these features of medium brightness, such as the sweat puddle 111 and the melting zone 113 , At the same time this leaves slightly longer exposure period 1250 not enough light energy from darker sections of the weld region 109 for the light sensors or detectors in the remaining outer sections 1288 the light sensor arrangement 1285 to get raw images of features in these darker sections of the weld region 109 to create. That's why the resulting raw picture shows 1250 ' that in this slightly longer exposure period 1250 is produced, only the quite bright, but not the brightest, features, such as the sweat puddle 111 and the melting zone 113 , The pixels of the central section 1291 of the raw picture 1250 ' are overexposed, and the remaining outer sections of the raw image 1250 ' include only dark pixels 1290 ,

The next, moderately longer exposure period 1256 causes an even larger overexposed central portion 1286 the light sensor arrangement 1285 because the light energy, not only by the brightest features, such as the arc 107 , the plasma 108 and the droplet 121 but also from the slightly darker features, such as the sweat puddle 111 and the melting zone 113 , radiated or reflected, the light sensors or detectors of the light sensor array 1285 in this even larger central section 1286 overexposed. At the same time this moderately longer exposure period offers 1256 an ideal light energy radiation for light sensors or detectors in a central section 1287 around the overexposed central section 1286 the light sensor arrangement 1285 around, because the light energy coming from the features in this central section of the weld region 109 , such as the electrode 106 and the workpieces 110 . 112 is radiated or reflected in an appropriate range for the light sensors or detectors of the light sensor array 1285 to which this light energy is focused lies to produce image pixels of these features. The darker outer portions of the weld region 109 do not emit or reflect enough light energy for the light sensors or detectors in the outer sections 1288 the light sensor arrangement 1285 to create pictures. That is why the raw picture has 1256 ' that through the light sensor assembly 1285 in this moderately longer exposure period 1256 a good resolution of these features of medium brightness, such as the electrode 106 and the workpieces 110 . 112 , At the same time this moderately longer exposure period 1256 not enough light energy from darker sections of the weld region 109 for the light sensors or detectors in the remaining outer sections 1288 the light sensor arrangement 1285 to get raw images of features in these darker sections of the weld region 109 to create. That's why the resulting raw picture shows 1256 ' that in this moderately longer exposure period 1236 is produced, only the moderately bright features, such as the sweat puddle 111 and the melting zone 113 , The pixels of the central section 1291 of the raw picture 1236 ' are overexposed, and the remaining outer sections of the raw image 1236 ' include only dark pixels 1290 ,

The next, longest exposure period 1262 causes an even larger overexposed central portion 1286 the light sensor arrangement 1285 because the light energy of all but the darkest features, such as the arc 107 , the plasma 108 , the droplet 121 , the sweat puddle 111 , the melting zone 113 , the electrode 106 and the inner sections of the workpieces 110 . 112 , radiated or reflected, the light sensors or detectors of the light sensor array 1285 in this even larger central section 1286 overexposed. At the same time, this offers the longest exposure period 1262 an ideal light energy radiation for light sensors or detectors in an outer section 1287 around the overexposed central section 1286 the light sensor arrangement 1285 around, because the light energy coming from the features in this outer section 1287 the welding region 109 , such as the welding nozzle 104 and the outer sections of the workpieces 110 . 112 is radiated or reflected in an appropriate range for the light sensors or detectors of the light sensor array 1285 to which this light energy is focused lies to produce image pixels of these features. The cooled and solidified weld bead 103 , in 12D not visible, would also be in the raw picture 1262 be seen if the camera is in a suitable perspective to the weld bead 103 to have in the field of vision. That is why the raw picture has 1262 ' that through the light sensor assembly 1285 in this longest exposure period 1262 a good resolution of these features of medium brightness, such as the welding nozzle 104 , the outer sections of the workpieces 110 . 112 and the welding bead 103 , That's why the resulting raw picture shows 1262 ' that in this longest exposure period 1262 is produced, only the darker features, such as the welding nozzle 104 , the outer sections of the workpieces 110 . 112 and the welding bead 103 , The pixels of the central section 1291 of the raw picture 1262 ' are overexposed.

The detection of previously determined currents in the decay phase 1211 the energy waveform 1202 can for the initiation current thresholds 1263 . 1264 . 1265 . 1266 for the exposure periods 1244 . 1250 . 1256 1262 with a time delay to the initiation trigger points 1267 . 1268 . 1269 . 1270 be used. For example, the initiation current thresholds may become 1263 . 1264 . 1265 . 1266 where there is a detectable current drop from the peak current phase 1209 with a time delay to desired exposure initiation trigger points 1267 . 1268 . 1269 . 1270 gives. Alternatively, special initiation current thresholds may occur at the specific positions in the decay phase 1211 the energy waveform 1202 where the exposure periods 1244 . 1250 . 1256 1262 be set to be initiated; in this case, the trigger points would be 1267 . 1268 . 1269 . 1270 the initiation current thresholds. The termination trigger points 1271 . 1272 . 1273 . 1274 are also limited to respective time delays from the respective initiation thresholds 1231 . 1232 . 1233 . 1234 may be adjusted as desired for particular purposes or effects, or they may be set to a particular detectable completion threshold level. The raw pictures 1244 ' . 1250 ' . 1256 ' . 1262 ' through the camera 126 during the respective exposure periods 1244 . 1250 . 1256 1262 are merged together to form the composite image 1280 to create. The composite picture 1280 shows the droplet 121 of molten metal coming from the distal end of the electrode 106 is separated and in the direction of the sweat puddle 111 falls because of this phenomenon during the decay phase 1211 the energy waveform 1202 occurs, which is at the position where the exposure periods 1244 . 1250 . 1256 1262 are located. Any of the composite image generation processes discussed above may be used to enhance the composite image 1280 from the raw pictures 1244 ' . 1250 ' . 1256 ' . 1262 ' to create. As by the examples of 12B . 12C and 12D illustrates different features in the weld region 109 be recorded and displayed by the exposure period at different phases of the energy waveform 1202 is positioned. In the composite picture 1240 ( 12B ) is the droplet 121 shown so that it just begins to be at the distal end of the welding electrode 106 to form while the composite image 1260 ( 12C ) the droplet 121 completely formed and just before detachment from the electrode 106 shows; and the composite picture 1280 shows the droplet 121 from the electrode 106 separated and in the middle of the fall in the direction of the sweat puddle 111 , These and many other phenomena in a welding process can be done with the camera 126 by shifting the exposure periods so that they are aligned with different phases of the energy waveform. If a series of composite images resulting from exposure periods in a certain phase of the energy waveform 1202 During a welding operation, as viewed in a continuous series, such as in rapid succession as successive frames in a video, such as 24 to 30 composite frames per second, these phenomena occurring in that particular phase may occur the display device in real time. Or in other words: that on the display device 138 displayed composite image may appear as a single image, but it is in fact a continuous sequence of composite images that are displayed in rapid succession, such as 24 to 30 frames per second, perceived by the human eye and brain as a single image become. Shifts the exposure periods to another phase of the energy waveform 1202 Thus, this may allow the user to view other features and phenomena of the welding process in real time. Such phase shifts of the exposure periods may be in increments, or they may be done in a continuous sweep of the energy waveform phases. For example, a slow dynamic shift of the exposure periods 1244 . 1250 . 1256 . 1262 in 12D over all phases in an entire cycle of the energy waveform 1202 away, ie from the flat ground phase 1205 about the rise phase 1207 , the peak current phase 1209 , and the decay phase 1211 down to the flat basic current phase 1205 , a video of the droplet 121 generate, which is at the distal end of the electrode 106 begins to form and continues to form a fully formed droplet 121 developed, extending from the electrode 106 triggers and into the puddle 111 falls. On the other hand, the exposure periods could 1244 . 1250 . 1256 . 1262 even while the composite images are viewed as a video, to a static position in the decay phase 1211 be adjusted, with the result that the composite image is the droplet 121 at the moment of reaching the sweat puddle 111 shows. Will then this position for the exposure periods 1244 . 1250 . 1256 . 1262 In other words, a welder, such as a person performing manual welding, could view a real-time video of the weld while holding the tip and electrode of the welder right where the video is the droplet 121 when hitting the puddle 111 shows.

The embodiments of the present invention therefore provide systems and methods for viewing the welding process and generating combined images having a high visual dynamic range. These techniques can be used in automated welding systems, such as in 1 illustrated automated welding vision and control system 100 , as well as in manual systems, such as the manual welding vision system 1300 , this in 13 is illustrated and described below. The high visual dynamic range of the system allows viewing of various sections of the weld during the welding process as well as the background. The composite images therefore provide a wealth of information about the quality of the weld, allowing adjustment of parameters to achieve high quality welds.

As mentioned above, the in 1 optional dynamic dimming disc shown 130 be used for the light intensities emitted by the arc 107 , the plasma 108 , the welding droplet 121 , the sweat puddle 111 and other features in the weld region 109 radiate and those on the light detector elements of the camera 126 impinge, in addition to control. The optional dynamic dimming disc 130 can through the visual system control unit 124 be controlled to attenuate light energy coming from the weld region 109 or features in the weld region 109 is emitted or reflected. This controls the optional dynamic Abdunkelungsscheibe 130 in addition the exposure of the camera 126 to either the aperture of the camera 126 and the sensitivity of the light detector elements of the camera 126 or can be used on its own without the aperture size or sensitivity of the camera's light detector elements 126 to adjust. Furthermore, the optional dynamic dimming disc 130 be operated in such a way that they only for a short time during the initial ignition of the arc 107 which it comes on top of the energy pulse, and is activated for a short time after the peak. The exemplary dynamic dimming disc 130 in the exemplary welding and vision control system 100 can be made, for example, from polymer-dispersed liquid crystal (PDLC) film materials which are available on the open market and have a variable light transmission which reacts very rapidly to changes in the applied voltage. Liquid crystal shading filter for cameras, which also has the function of the dimming disc 130 are available on the open market, for example from IC-Tech Display AB of Borlänge, Sweden. In this way, the control unit 124 in a simple way the dynamic dimming disc 130 by applying a control voltage signal. For example, a dimming disc control signal acting as a negative of the power waveform of the welding power supply 122 is generated, to the disc 130 be applied to incoming light for the camera 126 to condition to produce a uniform light intensity. Other variations of the dimming control signal are possible. The vision system controller 124 is programmed to initiate and terminate trigger control signals to the camera 126 and the dimming control signals with the raw image output of the camera 126 to synchronize. Alternatively, the exposure periods for each raw image could be kept constant for some or all of the raw images used to produce a composite image, while either the translucency of the shading disk 130 or the photosensitivity of the photosensor array in the camera 126 or a combination of both may be progressively increased or decreased for successive raw images to increase the likelihood that all features in the weld region 109 be effectively included in at least one or more of the raw images. The user interface 128 is also with the vision system controller 124 connected, so the user interface 128 can be used for the permeability of the dynamic darkening disc 130 as well as other operating parameters of in 1 illustrated weld vision and control system 100 to vary. The optional camera 127 can also use a dynamic dimming disc 131 equipped and used in the same way as above for the camera 126 is described.

1 further illustrates an optional optical detector 132 , The optional optical detector 132 can be used to detect the initial firing of each welding pulse to be in the 2 - 5 initiate illustrated processes. The optional optical detector 132 is with the vision system controller 124 coupled to the vision system control unit 124 to signal that at this moment a welding pulse was detected. A precise timing of the exposure can then optionally also by means of the optical detector 132 generated signal are triggered. The optional optical detector 132 can also trigger the event in the image processing control unit 124 produce.

An exemplary manual welding vision system 1300 that is equipped with some or all of the features and capabilities described above, including features and capabilities, for example 1 , is graphically in 13 illustrated. A welder 1318 is so illustrated that he has a hood 1302 carries on its inside a display device 1304 Has. The display device 1304 speaks to the cameras 1306 and the electronics package 1308 as above with respect to the cameras 126 . 127 and the vision system controller 124 in 1 has been described. the welder 1318 uses a manual arc welder 1310 to a welding bead 1312 at the intersection of the workpieces 1314 . 1316 to create. The manual arc welder 1310 is done by the welder 1318 controlled the welding process in the welding region 1209 on the display device 1304 tracked in real time. The two cameras 1306 Optional with darkening discs such as the darkening discs 130 . 131 in 1 be equipped, generate simultaneous raw images of the weld region 1209 or features in the weld region 1209 from the two different perspectives of the cameras 1306 to produce two composite images for stereoscopic viewing, although only a single camera needs to be used for monoscopic viewing. The raw images of the two cameras 1306 be through the electronics package 1308 as explained above, to generate two respective composite images of the two perspectives, and the two composite images are simultaneously displayed on the display device 1304 displayed, such as a single composite image from a single perspective to display for one of the person's eyes, and the second composite image from the second perspective to display for the other person's eye, creating or enhancing the illusion of 3D depth , Of course, a monoscopic display would present a composite image from a single camera to both eyes. The composite images, whether stereoscopic or monoscopic, allow the welder 1318 , Features in the weld region that emit or reflect high-intensity light energy (eg, the arc, the plasma, etc.), and features that emit or reflect less bright features (e.g., the molten droplets and puddles) and something darker features (e.g., the weld bead, the workpieces joined by the weld, etc.) in real time as the welding process proceeds. That way, the welder can 1318 see the environment and the background and also the plasma, the droplets from the manual arc welder 1310 , the puddles and other important sections or features of the resulting weld 1312 in real time during the welding process. That way, the hood needs 1302 no semi-transparent glass window, as the welder 1318 simply the display device 1304 on the inside of the hood 1302 and can see the whole process with high visual dynamic range, which is not possible with a typical welding hood that only looks through darkened glass.

The above description of the invention is for the purpose of illustration and description. It should not be exhaustive, nor should it limit the invention to the specific form disclosed. In light of the above teachings, other modifications and variations may be possible. The embodiment has been chosen and described as best explaining the principles of the invention and its practical application so as to enable others skilled in the art to embrace the invention in various embodiments and various modifications suitable for the specific intended use. optimal use. The words "comprising," "comprising," "comprising," "containing," "containing," and "containing" when used in this specification, including the features, are intended to indicate the presence of said features, integers, components, or the like They denote steps, but they do not preclude the presence or addition of one or more other features, integers, components, steps, or groups thereof. It is intended that the appended claims be construed to include other alternative embodiments of the invention, if not already included in the prior art.

Claims (59)

Welding vision and control system ( 100 ) for an arc welding system ( 102 ), wherein the arc welding system by a cyclic energy waveform ( 136 . 202 . 302 . 402 . 502 . 1002 . 1202 ) from a welding power supply ( 122 ) is supplied to a welding bead on a workpiece ( 110 . 112 ) in a welding region ( 109 ), and comprising: a camera ( 126 ) having a light sensor arrangement which is directed to the welding region or to a feature ( 103 . 104 . 106 . 107 . 108 . 110 . 111 . 112 113 ) in the weld region, the camera being responsive to exposure initiation control signals for irradiating the light sensor assembly with light energy emitted or reflected from the weld region or feature in the weld region to form a series of raw images (Fig. 204 ' . 304 ' . 404 ' . 504 ' . 1004 ' . 1224 ' ) of the weld region or feature in the weld region, and a vision system controller ( 124 ) which generates the exposure initiation control signals to the camera at a predetermined trigger point on a cyclic energy waveform. A welding vision and control system according to claim 1, including an electrical property sensor ( 123 ), which detects an electrical property (V, I) in the cyclic energy waveform, and wherein the vision system controller sets an exposure initiation threshold ( 228 . 238 . 428 . 528 . 1231 ) is detected in the cyclic energy waveform and in response generates the exposure initiation control signals to the camera. The welding and control system of claim 1, wherein the welding power supply generates the exposure initiation control signals to the camera in synchronism with a predetermined trip point on the cyclic energy waveform. The welding vision and control system of claim 2, wherein the camera exposes the light sensor array to light energy emitted or reflected from the weld region or feature in the weld region over an exposure period (FIG. 204 . 304 . 404 . 504 . 1224 ) at a phase of the cyclic energy waveform. The welding vision and control system of claim 4, wherein the vision system controller generates the exposure initiation control signals to the camera at predetermined time delays after detecting when the electrical characteristic (V, I) in the cyclic energy waveform matches the exposure initiation threshold. The welding vision and control system of claim 2, wherein the camera is responsive to exposure termination control signals to terminate exposure periods during which the light sensor assembly is irradiated with the light energy emitted or reflected from the weld region or feature in the weld region. The welding vision and control system of claim 6, wherein the vision system controller generates the exposure completion control signals to the camera at predetermined time delays after detecting when the electrical characteristic in the cyclic energy waveform matches the exposure initiation threshold. The welding vision and control system of claim 6, wherein the vision system controller detects when the electrical characteristic in the cyclic energy waveform matches exposure completion thresholds, and in response generates the exposure completion control signals to the camera. The welding vision and control system of claim 2, wherein the light sensor array comprises individual light sensors, each of which is illuminated with a discrete portion of the light energy emitted or reflected from the weld regions or feature in the weld region during an exposure period (FIG. 204 . 304 . 404 . 504 . 1004 . 1224 ), and wherein the camera irradiates the light sensor array with light energy emitted or reflected from the weld region or feature in the weld region in a sequence of the exposure periods to produce each of the respective raw images in the row of raw images in a pixel array format wherein each pixel in the pixel array format has a pixel value representative of the light energy absorbed by one of the light sensors in the light sensor array during a respective one of the exposure periods. The welding vision and control system of claim 9, wherein the vision system controller unites a plurality of first ones of the raw images into a first composite image (Fig. 253 . 397 . 476 . 576 . 1031 . 1240 merges by performing logical operations that select pixels from the multiple raw images, the non-overexposed pixel values (FIG. 942 . 944 . 946 ) and non-underexposed pixel values ( 952 . 954 . 956 ), and merge the selected pixels into the first composite image. A welding vision and control system according to claim 10, wherein the vision system controller sets second and subsequent multiple of the raw images into a second and subsequent composite images ( 255 . 398N . 478 . 578 . 1032 . 1260 ) merges by performing logical operations that select pixels of the second and subsequent multiple raw images that have non-overexposed pixel values and non-underexposed pixel values, and merge the selected pixels into the second and subsequent composite images. The welding vision and control system of claim 11, wherein the vision system controller sequentially couples the first, second, and subsequent composite images to a display device (12). 138 ) streams to the video display on the display device. The welding vision and control system of claim 12, which includes a user interface ( 128 ) connected to the vision system controller for inputting visual control parameters to the vision system controller. The weld vision and control system of claim 13, wherein the vision system controller is programmed to receive inputs from the user interface to change the phase of the cyclic energy waveform at which the exposure period occurs, and in response thereto, the exposure initiation threshold or the time delay after Change detection of the exposure initiation threshold in the cyclic energy waveform to generate the exposure initiation control signal or the exposure completion control signal to the camera. The weld vision and control system of claim 11, wherein the vision system controller performs logical operations that apply structure recognition or analysis to the second and subsequent composite images to identify a deviation from a preset parameter of one or more of the features in the weld region, and in response to the identification of the deviation outputs one or more signals to the welding power supply to modify a parameter of the cyclic energy waveform in a manner that corrects the deviation. The weld vision and control system of claim 11, wherein the vision system controller performs logical operations that apply structure recognition or analysis to the second and subsequent composite images to identify a deviation from a preset parameter of one or more of the features in the weld region, and in response to the identification of the deviation, outputs one or more signals to a robotic system controller to determine a physical parameter of the robot Arc welding system ( 102 ) in a manner that corrects the deviation. The weld vision and control system of claim 11, wherein the vision system controller performs logical operations that apply structure recognition or analysis to the second and subsequent composite images to identify a deviation from a preset parameter of one or more of the features in the weld region, and in response to the identification of the deviation, issue one or more alarm or notification signals to the display device or an alarm or notification system that identifies the deviation. A welding vision and control system according to claim 2, wherein the camera is a dimming disc ( 130 ) which adjusts dynamic light transmission in response to a transmission control signal. The welding vision and control system of claim 18, wherein the vision system controller generates the transmission control signal to the camera dimming disk. The weld vision and control system of claim 19, wherein the vision system controller generates the transmission control signal as a negative of the cyclic energy waveform. The welding vision and control system of claim 2, wherein the light sensor assembly has an adjustable sensitivity to light energy that can be controlled by a sensitivity control signal generated by the vision system controller. The welding vision and control system of claim 2, wherein the camera has an adjustable aperture that can be controlled by an aperture control signal generated by the vision system controller. Method for generating a series of raw images ( 204 ' . 304 ' . 404 ' . 504 ' . 1004 . 1224 ' ) a welding region ( 109 ) or a feature ( 103 . 104 . 106 . 107 . 108 . 110 . 111 . 112 113 ) in the welding region during a welding process that is characterized by a cyclic energy waveform ( 136 . 202 . 302 . 402 . 502 . 1202 ), in which an electrical characteristic (V, I) varies cyclically, and comprising: focusing a camera ( 126 to the weld region or feature in the weld region, and triggering the camera to project a light sensor assembly in the camera with light energy emitted or reflected from the weld region or feature in the weld region over a sequence of exposure periods (FIG. 204 . 304 . 404 . 504 . 1004 . 1224 ) to generate the raw images of the weld region or feature in the weld region in predetermined phases of the cyclic energy waveform. The method of claim 23, including triggering the camera to irradiate the light sensor array in the camera with the light energy radiated or reflected from the weld region or feature in the weld region over the sequence of exposure periods around the raw images of the weld region or the feature in the weld region at the predetermined phases of the cyclic energy waveform in response to the detection of a predetermined exposure initiation threshold of the electrical property in the cyclic energy waveform. The method of claim 23, including triggering the camera to detect the light sensor array in the camera with the light energy radiated or reflected from the weld region or feature in the weld region at predetermined time delays after detection of the electrical property exposure initiation threshold to irradiate the cyclic energy waveform. The method of claim 23, including providing different initiation thresholds for some of the exposure periods to control irradiation of the light sensor array in the camera with the light energy radiated or reflected from the weld region or feature in the weld region at the various phases of the light initiate cyclic welding current waveform. The method of claim 23, including providing some of the exposure periods with a different duration than other of the exposure periods to, to the light sensor assembly with the light energy radiated or reflected from the weld region or feature in the weld region over other phases of the cyclic energy waveform irradiate. The method of claim 23, including triggering the camera to complete the image exposure periods at predetermined time delays after detection of the electrical property exposure initiation threshold in the cyclic energy waveform. The method of claim 23, including triggering the camera to time the image exposure periods in response to the detection of predetermined exposure completion thresholds of the electrical property in the cyclic End energy waveform for the respective image exposure periods. Method for generating a raw image ( 204 ' . 304 ' . 404 ' . 504 ' . 1224 ' ) a welding region ( 109 ) or a feature ( 103 . 104 . 106 . 107 . 108 . 110 . 111 . 112 113 ) in the welding region during a welding process that is characterized by a cyclic energy waveform ( 136 . 202 . 302 . 402 . 502 . 1202 ), in which an electrical characteristic (V, I) varies cyclically, and comprising: focusing a camera ( 126 to the weld region or feature in the weld region, the camera being responsive to an exposure initiation control signal for initiating exposure of a light sensor array in the camera to light energy emitted or reflected from the weld region or feature in the weld region over an exposure period ( 204 . 304 . 404 . 504 . 1004 . 1224 ) to generate the raw image of the weld region or feature in the weld region; Detecting an exposure initiation threshold ( 228 . 238 . 428 . 528 . 1004 . 1231 ) of the electrical property in the cyclic energy waveform; and generating the exposure initiation control signal in response to the detection of the exposure initiation threshold of the electrical property in the cyclic energy waveform. The method of claim 30, including generating the exposure initiation control signal at a predetermined time delay after detection of the initiation threshold in the cyclic energy waveform. The method of claim 30, wherein the camera is responsive to an exposure completion control signal for terminating irradiation of a light sensor array in the camera with light energy radiated or reflected from the weld region or feature in the weld region. The method of claim 32, including detecting an exposure completion threshold of the electrical property in the welding current waveform and generating the exposure completion signal to the camera in response to the detection of the exposure termination threshold in the cyclic energy waveform to control the irradiation of the light sensor assembly in the camera with light energy is emitted or reflected from the welding region or feature in the welding region. The method of claim 32, including generating the exposure termination control signal at a predetermined time delay after detection of the electrical property exposure initiation threshold in the cyclic energy waveform. Method for viewing a specific feature ( 103 . 104 . 106 . 107 . 108 . 110 . 111 . 112 113 ) in a welding region ( 109 ) during a welding process that is characterized by a cyclic energy waveform ( 136 . 202 . 302 . 402 . 502 . 1202 ), in which an electrical characteristic (V, I) varies cyclically, and comprising: focusing a camera ( 126 ) to the weld region, the camera being exposed to exposure initiation control signals for initiating irradiation of a light sensor array in the camera with light energy radiated or reflected from the feature in the weld region over a sequence of exposure periods (Fig. 204 . 304 . 404 . 1004 . 1224 ), generating the exposure initiation control signals for irradiating the light sensor array with light energy emitted or reflected from the weld region during the periods of a first phase of the cyclic energy waveform to produce a series of composite images ( 255 . 398 . 478 . 578 . 1032 . 1260 ) from the sequence of exposure periods, streaming the series of composite images ( 255 . 398 . 478 . 578 . 1032 . 1260 ) the feature to a display device for a video display of features in the weld region as the features exist during the first phase of the cyclic energy waveform; and changing the exposure periods to occur in other phases of the cyclic energy waveform until the exposure periods occur in a phase in which the particular feature exists, such that the particular feature in the series of composite images (FIG. 255 . 398 . 478 . 578 . 1032 . 1260 ) on the video display device ( 140 ) will be shown. Method for generating a video of a welding process from a series of composite images ( 255 . 398 . 478 . 578 . 1032 . 1260 ) through a camera ( 126 ), and comprising: applying a plurality of operating parameters to a first operating mode of a video camera ( 126 ) for generating multiple sets of frames ( 204 ' . 304 ' . 404 ' . 504 ' . 1224 ' ) of the welding process, using a waveform generated by an arc welder performing the welding process to synchronize the plurality of sets of frames with the welding process by: providing first trigger pulses at a first set of positions (FIG. 228 . 352 . 428 . 528 . 1217 ) on the waveform in response to the Operating parameters used to open the shutter of the camera such that each of the frames in each set of frames of frames has a corresponding frame in other sets of frames fired at substantially the same position on the waveforms, producing second Triggering impulses at a second set of positions ( 230 . 354 . 430 . 530 . 1217 ) on the waveform in response to the operating parameters used to close the shutter of the camera so that each of the frames in each set of sets of frames has a corresponding image in other sets of frames, the substantially same exposure period has, generating the series of the combined images from the plurality of sets of frames by combining the frames in the sets of frames to produce the combined images, generating the video of the welding process from the series of the combined images, analyzing the video of the welding process to provide an analysis of the welding process, and modifying the welding process in response to the analysis. The method of claim 36, wherein the process of generating first trigger pulses comprises generating first trigger pulses that occur substantially at the same position on the waveform for all frames. The method of claim 36, wherein the process of generating first trigger pulses comprises generating first trigger pulses that occur at different positions on the waveform within each of the sets of frames. The method of claim 37, wherein the process of generating second trigger pulses comprises generating second trigger pulses that occur at substantially the same position on the waveform for all frames. The method of claim 38, wherein the process of generating second trigger pulses comprises generating second trigger pulses that occur at substantially the same position on the waveform for all frames. The method of claim 37, wherein the second trigger pulse generation process comprises generating second trigger pulses that occur at different positions on the waveform within each of the sets of frames. The method of claim 38, wherein the second trigger pulse generation process comprises generating second trigger pulses that occur at different positions on the waveform within each of the sets of frames. The method of claim 36, further comprising displaying the video. The method of claim 36, further comprising illuminating background areas surrounding the welding process with lamps such that the background area appears in the video. The method of claim 36, wherein the process of generating first trigger pulses comprises setting thresholds and detecting when the waveform reaches the thresholds. The method of claim 45, wherein the process of generating second trigger pulses comprises setting thresholds and detecting when the waveform reaches the thresholds. The method of claim 45, wherein the process of generating second trigger pulses comprises using delay periods extending from the first trigger pulses. The method of claim 36, further comprising applying a plurality of operating parameters to a second mode of operation of the video camera. A system for generating a video of a welding process, comprising: a wire feeding welder ( 102 ), the metallic weld pieces ( 110 . 112 ) welds to a weld ( 103 ), a welding power supply ( 132 ) having a power supply waveform ( 136 ), which is fed into the welder, a camera ( 126 ), which has a shutter and is adapted to generate a plurality of sets of frames of the welding process, a control unit ( 124 ) which detects the power supply waveform and first trip pulses at a first set of positions (FIG. 228 . 352 . 428 . 528 . 1217 ) are generated on the waveform used to open the shutter of the camera such that each of the frames in each set of the plurality of sets of frames has corresponding images in the plurality of sets of frames that are at a substantially same position on the frame Waveform and second trigger pulses at a second set of positions ( 230 . 354 . 430 . 530 . 1217 ) are generated on the waveform used to close the shutter of the camera so that each of the frames in each set of the plurality of sets of frames has corresponding images in the plural sets of frames that are substantially the same Exposure periods ( 204 ) which begin at substantially the same position on the waveform, the controller performs logical operations to combine frames in each set of frames to produce combined images suitable for display and analysis. The system of claim 49, wherein the controller generates the first trigger pulses such that the first set of positions on the waveform in each set of frames are substantially the same. The system of claim 49, wherein the controller generates the first trigger pulses such that at least some of the first set of locations on the waveform are different in each set of frames. The system of claim 50, wherein the control unit generates the second trigger pulses such that the second set of positions on the waveform in each set of frames are substantially the same. The system of claim 50, wherein the control unit generates the second trigger pulses such that at least some of the second set of locations on the waveform are different in each set of frames. The system of claim 51, wherein the controller generates the second trigger pulses such that at least some of the second set of locations on the waveform are different in each set of frames. The system of claim 49, further comprising a display device for displaying the combined images. The system of claim 49, further comprising lamps that illuminate welds so that the welds are seen in the combined images. The system of claim 49, wherein the control unit detects the power supply waveform and generates the first trip pulses by comparing a threshold value with the power supply waveform. The system of claim 49, further comprising a plurality of shift registers that temporally align pixels of a plurality of pixel streams for each image in each set of the plurality of sets of frames. The system of claim 49, wherein the control unit comprises a plurality of comparators that select pixels for the combined image based on an illumination value of the pixel.

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