Attaining a good image of a weld and the surrounding background has been a struggle ever since video cameras for welding became available. The problem has always been the range of brightness that occurs during welding: the ratio between the maximum and minimum light intensity is usually too great for a standard camera to measure properly. Standard cameras on the market today can typically measure about 1,000 levels of brightness between the maximum and minimum light levels in an image. However, in a typical open arc welding environment, there is a brightness range that can exceed 10,000,000 levels of brightness between the brightest portion of the welding arc, and the darker areas surrounding the weld. Using a standard camera to image such a weld will create an image similar to the image below on the left, where the camera sensor will image the scene up to a point and then saturate when it gets too bright. This causes the bright areas of the image to appear as a white blur.
To solve this problem, Xiris Automation has developed the XVC-O View Camera that uses advanced electronics with logarithmic sensitivity to be able to see more than 10,000,000 levels of brightness in an image. As a result, more image detail is visible than ever seen before. The detail of the weld arc, the shielding gas, weld pool, torch tip, and weld seam can all clearly be seen. The image below on the right is an image taken from the XVC-O camera of an open arc welding process. The weld arc is no longer saturated and is clearly visible as is the detail of the background, providing better quality information for the weld operator.
Standard Camera Image of a Weld Xiris XVC-O Camera Image of a Weld
With the ability to see more detail of the weld arc and the surrounding environment, welding technicians are able to use the XVC-O to better control their welding processes through better quality assurance and process feedback.
To see examples of the video quality possible with the XVC-O across a variety of welding processes and materials, please see our Weld Video Library here.