In the world of industrial processes, speed matters. The faster a process occurs, the more efficient the production line or manufacturing process. However, increasing speed can create unique challenges, especially when attempting to understand, monitor, and troubleshoot rapid phenomena. As this article shall explain, high-speed imaging illumination provides a lens through which to view the intense brightness of exothermic processes and accurately image shockwaves, flows, and various physical events in manufacturing. In doing so, high-speed imaging illumination revolutionizes the way we perceive and analyze industrial operations, offering a method for improving processes.1
Clear Visibility: A New Perspective on Fast-Moving Objects
By capturing multiple frames in quick succession, high-speed imaging essentially “freezes” motion, allowing for a detailed and unobstructed view of an object’s trajectory and behavior. Proper illumination further complements this process by providing the necessary light intensity and direction to illuminate the object precisely at each captured frame. This approach ensures that even in situations where conventional imaging methods would yield blurry or indistinct results, high-speed imaging with adequate illumination delivers clear, detailed, and actionable visual data.1
The enhanced visibility provided by high-speed imaging illumination allows researchers, engineers, and technicians to discern and analyze intricate dynamics and characteristics of fast-moving objects with unprecedented accuracy. This approach can identify potential defects or inefficiencies in a process, forming the basis of targeted troubleshooting. The outcome of this method can include quality enhancement, risk mitigation, improved operational efficiency and informed decision-making.
Improved Image Quality: The Role of CAVILUX Laser Illumination
Laser illumination, particularly CAVILUX laser systems, plays a fundamental role in enhancing the image quality of high-speed imaging systems. By using high-power, ultra-short laser pulses, motion blur is eliminated, resulting in crisp and clear images. The use of monochromatic and low-coherence light further ensures optimal image quality, devoid of chromatic aberrations or speckle.
This advancement allows for better image analysis and interpretation, offering a clearer window into phenomena understanding, reduced ambiguity of processes, and improvement in comparison studies.2
Freezing Motion: How to Capture the Unseen
Without additional light, images acquired at ultra high frames rates (MHz range) will be very dark and show motion blur.
By illuminating the scene with ultra-short laser pulses during each frame, one can obtain very bright and crisp images. Phenomena that were once a blur can now be captured in stunning detail through high-speed imaging illumination.2 This capability is a game-changer, especially in industries where minute details matter, such as aerospace or additive manufacturing. Temporal analysis of fast processes can reveal hidden dynamics, validate theoretical models by providing real-world data, and allow for motion trajectory mapping. The latter analysis is essential in understanding spattering paths, velocities, and accelerations critical for process optimization in the domain of additive manufacturing.3
Real-Time Visual Monitoring and Analysis: Illuminating the Benefits
Without special visualization techniques, the light produced by welding is too intense to be monitored by ordinary camera systems. However, Cavitar’s Welding Cameras, such as the C300 and C400, enable engineers to monitor welding processes in real time with unprecedented clarity. Capturing images up to 500 frames per second, these plug and play cameras can visualize melt pool behavior and filler material by seeing through the bright welding arc.
Cavitar C300 & C400 Welding Cameras incorporate built-in laser illumination and custom filtering optics. This unique technology enables real-time monitoring of welding processes. Early error detection translates into higher quality output and reduction of scrap – leading to significant economic savings.4
Additionally, the ergonomic advantages of these systems cannot be overlooked. Common risk factors to welders, such as repetitive injury and poor posture, can cause musculoskeletal injuries, reduced work quality and impede productivity.4,5 Not only can Cavitar systems be operated from a safe distance to the process, but welders can benefit from improved working ergonomics.4
A Bright Future for Industrial Processes
The combination of high-speed imaging and illumination lasers has opened a new era in industrial processes. Clear visibility rendered through “freezing” motion, improved image quality, and real-time monitoring are just a few of the remarkable advancements that are transforming industries. As pioneers in this field, Cavitar offers a suite of illumination systems and welding cameras that redefine how we perceive and interact with industrial operations.
Cavitar offers you “Value in Sight” with cutting-edge illumination systems and welding cameras. Our versatile products cater to a wide range of applications, from industrial visual process monitoring to scientific research. Whether you’re in R&D, an OEM manufacturer, or an end-user, our solutions are tailored to meet your unique needs. Discover how our high-speed imaging illumination solutions can revolutionize your industrial processes. Explore more at https://www.cavitar.com/
References and Further Reading
- Cavitar. Cavitar®HF: Laser light for high-speed imaging. Available at: https://www.cavitar.com/wp-content/uploads/2018/10/Cavilux_HF_esite_26102018_web.pdf (Accessed on 17 August 2023).
- Cavitar. Welcome to the Invisible World. Available at: https://www.cavitar.com/wp-content/uploads/2022/10/Cavilux-Schlieren-OEM_Cavitar_WEB.pdf (Accessed on 17 August 2023).
- Yin J, et al. (2020). Correlation between forming quality and spatter dynamics in laser powder bed fusion. Additive Manufacturing. https://doi.org/10.1016/j.addma.2019.100958
- Cavitar. Cavitar Welding Camera. Available at: https://www.cavitar.com/product/cavitar-welding-camera/ (Accessed on 17 August 2023).
- Nedohe K, et al. (2022). Assessment of Ergonomics Risk Experienced by Welding Workers in a Rail Component Manufacturing Organization. Flexible Automation and Intelligent Manufacturing: The Human-Data-Technology Nexus. https://doi.org/10.1007/978-3-031-18326-3_23
