US 2026/0295707 A1 · Omni-Directional Melt Pool Viewer

Abstract

An imaging system that achieves a 360°view around a welding torch using a method that combines multiple images into a single image so there is no obstruction from the welding torch or the welding torch electrode. The system uses two or more cameras to digitally combine multiple images into a single image focused via an arrangement of lenses and directing light via fiber optic light guides into a single camera. Thermal measurements are taken using the cameras, which are capable of detecting the wavelengths of light and performing thermal analysis. Data processing is provided to create a weld pool profile using a spectroscopic evaluation of the welding shielding gas. This system improves the arc additive manufacturing and welding process by monitoring the weld pool size and shape in real-time for identification of anomalies during the welding process that can lead to insufficient weld deposits and deleterious weld properties.

Claims20

Dependent claims

An imaging system for viewing a melt pool through a center of a welding torch, the imaging system capable of displaying a 360 degree view of the melt pool without obstruction by an electrode of the welding torch by combining multiple images from at least two cameras, the imaging system comprising:

a first camera, the first camera comprising a first camera lens, a first camera housing and being connected to a top of a camera assembly;
a second camera, the second camera comprising a second camera lens, a second camera housing and being connected to the top of the camera assembly;
a gas cup, the gas cup comprising a lower portion and being connected to a bottom of the camera assembly;
the welding torch, wherein the electrode of the welding torch extends into the gas cup, and further wherein the melt pool is created on a workpiece at an end of a contact tip of the welding torch during operation of the welding torch inside the gas cup;
and,
an image processing computer that receives image information from the first camera and from the second camera, and displays the 360 degree view of the melt pool without obstruction by the electrode or by the contact tip of the welding torch.

3 more elements

a first light guide, the first light guide comprising a first lens, a first coherent fiber bundle, a first housing and being connected to a top of a light guide assembly;
a second light guide, the second light guide comprising a second lens, a second coherent fiber bundle, a second housing and being connected to the top of the light guide assembly;
a gas cup, the gas cup comprising a lower portion and being connected to a bottom of the light guide assembly;
the welding torch, wherein the electrode of the welding torch extends into the gas cup, and further wherein the melt pool is created at a workpiece at an end of a contact tip of the welding torch during operation of the welding torch inside the gas cup;
and,
an image processing computer that receives image information from the first light guide and from the second light guide, and displays the 360 degree view of the melt pool without obstruction by the electrode or by the contact tip of the welding torch.

3 more elements

Dependencies are inferred from the claim text.

Omni-Directional Melt Pool Viewer

Life of this patent

Omni-Directional Melt Pool Viewer

Life of this patent

Abstract

Claims20