In-Process Monitoring of Lack of Fusion in Ultra-Thin Sheets Edge Welding Using Machine Vision
Lack of fusion can often occur during ultra-thin sheets edge welding process, severely destroying joint quality and leading to seal failure. This paper presents a vision-based weld pool monitoring method for detecting a lack of fusion during micro plasma arc welding (MPAW) of ultra-thin sheets edge...
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MDPI AG
2018-07-01
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| Series: | Sensors |
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| Online Access: | http://www.mdpi.com/1424-8220/18/8/2411 |
| _version_ | 1811301772685213696 |
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| author | Yuxiang Hong Baohua Chang Guodong Peng Zhang Yuan Xiangchun Hou Boce Xue Dong Du |
| author_facet | Yuxiang Hong Baohua Chang Guodong Peng Zhang Yuan Xiangchun Hou Boce Xue Dong Du |
| author_sort | Yuxiang Hong |
| collection | DOAJ |
| description | Lack of fusion can often occur during ultra-thin sheets edge welding process, severely destroying joint quality and leading to seal failure. This paper presents a vision-based weld pool monitoring method for detecting a lack of fusion during micro plasma arc welding (MPAW) of ultra-thin sheets edge welds. A passive micro-vision sensor is developed to acquire clear images of the mesoscale weld pool under MPAW conditions, continuously and stably. Then, an image processing algorithm has been proposed to extract the characteristics of weld pool geometry from the acquired images in real time. The relations between the presence of a lack of fusion in edge weld and dynamic changes in weld pool characteristic parameters are investigated. The experimental results indicate that the abrupt changes of extracted weld pool centroid position along the weld length are highly correlated with the occurrences of lack of fusion. By using such weld pool characteristic information, the lack of fusion in MPAW of ultra-thin sheets edge welds can be detected in real time. The proposed in-process monitoring method makes the early warning possible. It also can provide feedback for real-time control and can serve as a basis for intelligent defect identification. |
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| id | doaj.art-c621409e3ff940b69f3e9df5362eb4de |
| institution | Directory Open Access Journal |
| issn | 1424-8220 |
| language | English |
| last_indexed | 2024-04-13T07:16:03Z |
| publishDate | 2018-07-01 |
| publisher | MDPI AG |
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| series | Sensors |
| spelling | doaj.art-c621409e3ff940b69f3e9df5362eb4de2022-12-22T02:56:45ZengMDPI AGSensors1424-82202018-07-01188241110.3390/s18082411s18082411In-Process Monitoring of Lack of Fusion in Ultra-Thin Sheets Edge Welding Using Machine VisionYuxiang Hong0Baohua Chang1Guodong Peng2Zhang Yuan3Xiangchun Hou4Boce Xue5Dong Du6Key Laboratory for Advanced Materials Processing Technology, Ministry of Education, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, ChinaKey Laboratory for Advanced Materials Processing Technology, Ministry of Education, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, ChinaKey Laboratory for Advanced Materials Processing Technology, Ministry of Education, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, ChinaKey Laboratory for Advanced Materials Processing Technology, Ministry of Education, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, ChinaKey Laboratory for Advanced Materials Processing Technology, Ministry of Education, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, ChinaKey Laboratory for Advanced Materials Processing Technology, Ministry of Education, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, ChinaKey Laboratory for Advanced Materials Processing Technology, Ministry of Education, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, ChinaLack of fusion can often occur during ultra-thin sheets edge welding process, severely destroying joint quality and leading to seal failure. This paper presents a vision-based weld pool monitoring method for detecting a lack of fusion during micro plasma arc welding (MPAW) of ultra-thin sheets edge welds. A passive micro-vision sensor is developed to acquire clear images of the mesoscale weld pool under MPAW conditions, continuously and stably. Then, an image processing algorithm has been proposed to extract the characteristics of weld pool geometry from the acquired images in real time. The relations between the presence of a lack of fusion in edge weld and dynamic changes in weld pool characteristic parameters are investigated. The experimental results indicate that the abrupt changes of extracted weld pool centroid position along the weld length are highly correlated with the occurrences of lack of fusion. By using such weld pool characteristic information, the lack of fusion in MPAW of ultra-thin sheets edge welds can be detected in real time. The proposed in-process monitoring method makes the early warning possible. It also can provide feedback for real-time control and can serve as a basis for intelligent defect identification.http://www.mdpi.com/1424-8220/18/8/2411micro plasma arc weldingedge joint welddefects detectionweld pool monitoringlack of fusionmicro vision sensing |
| spellingShingle | Yuxiang Hong Baohua Chang Guodong Peng Zhang Yuan Xiangchun Hou Boce Xue Dong Du In-Process Monitoring of Lack of Fusion in Ultra-Thin Sheets Edge Welding Using Machine Vision Sensors micro plasma arc welding edge joint weld defects detection weld pool monitoring lack of fusion micro vision sensing |
| title | In-Process Monitoring of Lack of Fusion in Ultra-Thin Sheets Edge Welding Using Machine Vision |
| title_full | In-Process Monitoring of Lack of Fusion in Ultra-Thin Sheets Edge Welding Using Machine Vision |
| title_fullStr | In-Process Monitoring of Lack of Fusion in Ultra-Thin Sheets Edge Welding Using Machine Vision |
| title_full_unstemmed | In-Process Monitoring of Lack of Fusion in Ultra-Thin Sheets Edge Welding Using Machine Vision |
| title_short | In-Process Monitoring of Lack of Fusion in Ultra-Thin Sheets Edge Welding Using Machine Vision |
| title_sort | in process monitoring of lack of fusion in ultra thin sheets edge welding using machine vision |
| topic | micro plasma arc welding edge joint weld defects detection weld pool monitoring lack of fusion micro vision sensing |
| url | http://www.mdpi.com/1424-8220/18/8/2411 |
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