Description:METHOD FOR REAL-TIME ELEMENTAL QUANTIFICATION OF WELDING FUMES USING CAPTURED FLOW FIELD IMAGES

FIELD OF INVENTION
[001] The invention relates to real-time elemental analysis, utilizing spectral imaging on captured welding fume flow fields for precise quantification. This advances the understanding of chemical dynamics during welding processes.

[002] This invention in particular relates to Method for real-time elemental quantification of welding fumes using captured flow field images.
BACKGROUND OF INVENTION
[003] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.

[004] Welding processes are integral to diverse industries, serving as a cornerstone for the fabrication of structures and components. Fusion welding processes involve melting and joining of materials, which usually is an electric arc or power beams like laser & electron beam. The electric arc welding uses the heat generated from an electric arc stuck between the electrode and the base material for melting and joining the materials, wherein; the heat from the arc also results in generation of welding fumes comprising of various elements & compounds which may have a detrimental effect to the health of the welding personnel involved in making of the weld. The extent of the effect depends on various factors like composition of weldments, flux material, shielding gas used, etc. Hence, precise & quick analysis of the content of welding fumes will be helpful in designing safe environment for the welding personnel especially, welders. It additionally assists welders in fine-tuning parameters to enhance weld quality. Monitoring the elemental composition of weld fumes, underscore the need for innovative solutions.

[005] Conventional methods for assessing the elemental composition of weld fumes typically involve a laborious process and extensive post-weld analyses. This approach falls short in capturing the dynamic changes occurring during the welding process. Real-time insights into the evolving elemental composition are crucial for optimizing welding parameters and ensuring the quality of the final weld and the safety of the welder.

[006] Moreover, gaining access to the weld zone during the welding process for in-process monitoring presents a formidable challenge. The limited accessibility restricts the ability to conduct timely analyses, impacting the overall effectiveness of elemental monitoring.

[007] Welders, being at the forefront of welding operations, face potential health risks due to exposure to fumes and gases generated during the welding process. The safety of welders is a paramount concern in any welding operation. Real-time monitoring of the elemental composition of weld fumes is not only pivotal for enhancing welding processes but also critical for safeguarding the well-being of the welding workforce.

[008] The drawbacks of current methods compound the challenges in elemental analysis during welding operations. Post-weld analyses, being retrospective, cannot provide the necessary real-time data required for immediate decision-making. Additionally, the limited access to the weld zone hampers the ability to conduct in-process monitoring such as using a weld sampler in the breathing zone, leaving a significant gap in one’s ability to understand and control the dynamic nature of weld fumes.

PRIOR ART
[009] Limited work has been done for the fume analysis in welding applications. The compilation of the prior art search is presented below:

[0010] US patent US20120286958A1 relates to the welding helmets with real-time fume exposure monitoring, utilizing an air-sampling system and an intelligent warning apparatus. However, challenges such as sensor calibration, potential failures, maintenance requirements and power considerations are inherent.

[0011] US patent US10242317 relates to the weld fume analysis by collecting the fumes at different data points and uses the collective data to predict the amount of fume for the given welding parameter. However, limitations arise from potential inaccuracies in operational data, imprecise content estimates and delays in reporting due to data processing.

[0012] US patent 4287405 relates to the system that detects optical radiation emitted from the arc using a photoelectric device. The electric detection signal from this device controls a suction hood's movement along the weld line, ensuring effective exhaust of weld fumes and continuous coverage of the weld metal zone. Challenges may arise due to variations in arc radiation and precise synchronization between the photoelectric device and the suction hood, impacting optimal coverage.
DRAWBACKS OF PRIOR ARTS

[0013] All the prior arts mentioned are relying on operational data and sensor-based methods with inherent challenges become apparent in their susceptibility to inaccuracies and imprecise estimations. Challenges arise from calibration needs, sensor failures, and inherent delays in data processing.
[0014] These limitations hinder the effectiveness of exposure monitoring and compromise the precision of fume content estimates, emphasizing the need for a more real-time immediate insight in welding processes.
OBJECTS OF THE INVENTION

[0015] Primary object of the invention is to provide Method for real-time elemental quantification of welding fumes using captured flow field images, which obviates shortcomings of the prior art(s).

[0016] One object of the present invention is to ascertain the elemental composition within the welding fume.

[0017] Another objective of the present invention is to identify the presence of various chemical states or forms of an element.

[0018] Still another objective of the present invention is to deduce the temperature of the focal field by examining the spectra emitted.

[0019] Yet another objective of the present invention is to assess and measure the elemental volume using the acquired temperature field.

[0020] These and other objects and advantages of the present invention will be apparent to those skilled in the art after a consideration of the following detailed description taken in conjunction with the accompanying drawings in which a preferred form of the present invention is illustrated.

SUMMARY OF INVENTION

[0021] One or more drawbacks of conventional systems and process are overcome, and additional advantages are provided through the apparatus/composition and a method as claimed in the present disclosure. Additional features and advantages are realized through the technicalities of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered to be part of the claimed disclosure.
[0022] According to this invention, there is provided Method for real-time elemental quantification of welding fumes using captured flow field images comprises steps of:
- Capturing images of the hot fumes emitted during welding;
- loading the images;
- Processing the images using spectral imaging;
- isolating emission spectra details from hot fume gases.
[0023] The images are high-resolution images of the welding fume flow fields in real time.

[0024] The images are captured by a simple camera system.

[0025] The algorithm is designed to swiftly and accurately identify the presence, position and concentration of specific elements in the evolving weld fumes.

[0026] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

[0027] It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined to form a further embodiment of the disclosure.

[0028] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

[0029] The illustrated embodiments of the subject matter will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and processes that are consistent with the subject matter as claimed herein, wherein: -

[0030] Figure 1 shows: The first image, that captures the Gas Metal Arc Welding (GMAW) process with a high shutter speed and low light sensitivity (ISO), revealing the visibility of welding fumes in the Red - Green - Blue (RGB) spectrum. In the same figure, the second image provides a detailed zoomed-in view of a specific segment of the welding process, offering a closer examination of the fume dynamics in the weld vicinity.

[0031] Figure 2 shows: The emphasis lies on verifying the temperature field of the weld fume and its surroundings for further analysis. This step ensures selection criteria for RGB imaging, requiring fumes to surpass a temperature threshold. Higher temperature corresponds to heightened spectral signals, enhancing the accuracy of subsequent analysis.

[0032] Figure 3 shows: The focus is on refining the analysis area with precision. The depiction includes a white field image, a dark field image and the resultant image highlighting the area of interest. This step ensures meticulous delineation, enabling a detailed and accurate analysis of specific regions within the weld fume environment.

[0033] Figure 4 shows: The results obtained after applying the algorithm to each element. The first image displays the spectral image obtained for Manganese (Mn) and Iron (Fe), while the second image presents a comparison with the original image, highlighting the identified elements with color-coded representation.

[0034] The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAIL DESCRIPTION OF THE INVENTION WITH REFERENCE TO THE ACCOMPANYING DRAWINGS

[0035] While the embodiments of the disclosure are subject to various modifications and alternative forms, specific embodiment thereof have been shown by way of example in the figures and will be described below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the scope of the disclosure.

[0036] The current invention pertains to development of a simple and reliable methodology for real-time monitoring, and places a significant emphasis on the safety of welders exposed to welding fumes. The composition of the weld fume can also be used to assess the quality of the resultant weld by correlating the composition of weld fumes with the parameters like arc current & voltage. This can further serve as a tool to monitor if the qualified parameters are only used for welding.

[0037] The current invention presents an approach to overcome the limitations of existing methods. By employing emission spectroscopy, the invention enables real-time elemental analysis of weld fumes.

[0038] The invention proposed involves capturing images of the hot fumes emitted during welding and processing them using an algorithm developed exclusively for this purpose. The algorithm is designed to swiftly and accurately identify the presence, position, and concentration of specific elements in the evolving weld fumes.

[0039] Beyond the advancements in elemental analysis, the real-time nature of the invention ensures that safety concerns are promptly addressed. Rapid identification of elements allows for immediate intervention or adjustment of welding parameters, minimizing potential health risks to welders and better weld quality as well.
ADVANTAGES OF INVENTION

[0040] The present developed method utilizes real-time spectral-imaging (using a normal RGB camera). This method is not data dependent and it ensures immediate and accurate elemental analysis during welding, enhancing precision and providing insights for optimized process. This advancement addresses inherent issues of inaccuracy, spatial distribution data limitations, calibration needs and delays, making a substantial leap in both safety and efficiency.
[0041] In conclusion, the invention represents a significant leap forward in the field of welding processes and elemental analysis of weld fumes. The real-time capabilities offer a dynamic perspective into the elemental composition, empowering welders with timely information to enhance the quality of welding operations and, most importantly, ensuring their safety in real-time. The integration of emission spectroscopy into welding processes heralds a new era of efficiency, precision, and safety in welding operations.

[0042] Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases, it will be recognized that references to the "invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims.

[0043] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all groups used in the appended claims.

[0044] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particulars claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogues to “at least one of A, B and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B”.

[0045] The above description does not provide specific details of manufacture or design of the various components. Those of skill in the art are familiar with such details, and unless departures from those techniques are set out, techniques, known, related art or later developed designs and materials should be employed. Those in the art are capable of choosing suitable manufacturing and design details.

[0046] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. It will be appreciated that several of the above-disclosed and other features and functions, or alternatives thereof, may be combined into other systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may subsequently be made by those skilled in the art without departing from the scope of the present disclosure as encompassed by the following claims.

[0047] The claims, as originally presented and as they may be amended, encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants/patentees and others.

[0048] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
, Claims:We Claim
1. Method for real-time elemental quantification of welding fumes using captured flow field images comprises steps of:
- Capturing images of the hot fumes emitted during welding;
- loading the images;
- Processing the images using spectral imaging;
- isolating emission spectra details from hot fume gases.
2. The method as claimed in the claim 1, wherein the images are high-resolution images of the welding fume flow fields in real time.
3. The method as claimed in the claim 2, wherein the images are captured by a simple camera system.
4. The method as claimed in the claims 1-3, wherein the algorithm is designed to swiftly and accurately identify the presence, position and concentration of specific elements in the evolving weld fumes.