Binocular vision system for both weld pool and root gap in robot welding process

Abstract

PurposeThe purpose of this paper is to develop a kind of low cost measuring system based on binocular vision sensor to detect both the weld pool geometry and root gap simultaneously for robot welding process.Design/methodology/approachTwo normal charge coupled device cameras are used for capturing clear images from two directions; one of them is used to measure the root gap and another one is used to measure the geometric parameters of the weld pool. Efforts are made from both hardware and software aspects to decrease the strong interferences in pulsed gas tungsten arc welding process, so that clear and steady images can be obtained. The grey level distribution characteristics of root gap edge and weld pool edge in images are analyzed and utilized for developing the image processing algorithms.FindingsA solid foundation for seam tracking and penetration control of robot welding process can be established based on the binocular vision sensor.Practical implicationsThe results show that the algorithms can extract the root gap edges and the contour of weld pool effectively, and then some geometric parameters can be calculated from the results.Originality/valueThe binocular vision system provides a new method for sensing of robot welding process.

Stereo vision based measuring system for online welding path inspection

“…Wu et al (2004) developed a vision-based sensing and determination of the weld pool geometrical appearance during the gas-metal arc welding process in order to correlate the surface geometrical appearance of weld pool to the weld penetration and to calculate the prerequisites for process control. Ma et al (2010) developed a measuring system based on binocular vision sensor to detect both the weld pool geometry and root gap simultaneously for robot welding process.…”

Localization and measurement method of continuous casting slab model based on binocular vision

“…With the development of intelligence, it is an inevitable trend to use “binocular” to accurately perceive the information of surrounding environment. Ma et al used binocular vision system to monitor the welding seam in the process of welding. By analyzing the image grayscale level, locating the welding center and calculating the width of the welding seam, the intelligent production and automatic monitoring of welding quality can be realized.…”

ANFIS Modeling of Human Welder's Response to Three-Dimensional Weld Pool Surface in GTAW

“…Extensive researches have been performed to observe the weld pool using various sensing techniques [2][3][4][5][6][7][8]. Different types of information have been extracted and interpreted to describe the state of the welding process.…”