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Crack Monitoring in Resonance Fatigue Testing of Welded Specimens Using Digital Image Correlation

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Published on: September 29, 2019

A Precise Visual Method for Narrow Butt Detection in Specular Reflection Workpiece Welding.

Jinle Zeng¹, Baohua Chang², Dong Du³

¹Key Laboratory for Advanced Materials Processing Technology, Ministry of Education, Department of Mechanial Engineering, Tsinghua University, Beijing 100084, China. zengjl12@mails.tsinghua.edu.cn.

Sensors (Basel, Switzerland)

|September 21, 2016

Summary

This summary is machine-generated.

This study introduces a new visual seam detection method for automated welding. It effectively detects narrow grooves on reflective workpieces, improving torch alignment accuracy and enabling high-speed welding.

Keywords:

narrow butt seam tracking specular reflection workpiece welding visual detection welding process control

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Area of Science:

Robotics and Automation
Computer Vision
Materials Science

Background:

Accurate welding torch alignment is crucial for complex path workpiece welding.
Existing visual seam detection methods struggle with narrow grooves and specular reflection, leading to poor imaging quality and potential failures.
Automated correction of torch-groove deviation is essential for efficient and precise welding operations.

Purpose of the Study:

To propose a novel visual seam detection method for narrow butt welding of specular reflection workpieces.
To overcome limitations of existing methods caused by small groove widths and poor imaging quality.
To enable real-time, accurate detection and correction of welding torch position and pose relative to the groove.

Main Methods:

Designed a uniform surface light source to enhance signal-to-noise ratio and mitigate specular reflection effects.
Utilized a double-line laser light source to acquire the workpiece surface equation relative to the welding torch.
Implemented synchronized image capture with alternating light sources for simultaneous position and pose determination.

Main Results:

Achieved high signal-to-noise ratio images despite specular reflection.
Obtained workpiece surface equations for precise torch positioning.
Demonstrated effective and efficient groove detection with an image resolution of 12.5 μm.
Processed images in less than 10 ms per frame, suitable for real-time applications.

Conclusions:

The proposed method successfully addresses challenges in detecting narrow grooves on specular reflection workpieces.
The system enables simultaneous determination of torch-groove position and pose.
The method's speed and accuracy make it suitable for real-time narrow butt detection in high-speed welding processes.