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Sensors 2016, 16(9), 1480; doi:10.3390/s16091480

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

Key Laboratory for Advanced Materials Processing Technology, Ministry of Education, Department of Mechanial Engineering, Tsinghua University, Beijing 100084, China
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Author to whom correspondence should be addressed.
Academic Editor: Vittorio M. N. Passaro
Received: 21 July 2016 / Revised: 22 August 2016 / Accepted: 7 September 2016 / Published: 13 September 2016
(This article belongs to the Section Physical Sensors)

Abstract

During the complex path workpiece welding, it is important to keep the welding torch aligned with the groove center using a visual seam detection method, so that the deviation between the torch and the groove can be corrected automatically. However, when detecting the narrow butt of a specular reflection workpiece, the existing methods may fail because of the extremely small groove width and the poor imaging quality. This paper proposes a novel detection method to solve these issues. We design a uniform surface light source to get high signal-to-noise ratio images against the specular reflection effect, and a double-line laser light source is used to obtain the workpiece surface equation relative to the torch. Two light sources are switched on alternately and the camera is synchronized to capture images when each light is on; then the position and pose between the torch and the groove can be obtained nearly at the same time. Experimental results show that our method can detect the groove effectively and efficiently during the welding process. The image resolution is 12.5 μm and the processing time is less than 10 ms per frame. This indicates our method can be applied to real-time narrow butt detection during high-speed welding process. View Full-Text
Keywords: welding process control; seam tracking; specular reflection workpiece welding; narrow butt; visual detection welding process control; seam tracking; specular reflection workpiece welding; narrow butt; visual detection
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).

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MDPI and ACS Style

Zeng, J.; Chang, B.; Du, D.; Hong, Y.; Chang, S.; Zou, Y. A Precise Visual Method for Narrow Butt Detection in Specular Reflection Workpiece Welding. Sensors 2016, 16, 1480.

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