Extraction of Three-Dimensional Parameters for Weld Pool Surface in Pulsed GTAW With Wire Filler

[+] Author and Article Information
D. B. Zhao, J. Q. Yi

Laboratory of Complex Systems and Intelligence Science, Institute of Automation, Chinese Academy of Sciences, Beijing 100080, P. R. China

S. B. Chen

Institute of Welding Technology, Shanghai Jiao Tong University, Shanghai, 200030, P. R. China

L. Wu

National Key Laboratory of Advanced Welding Production Technology, Harbin Institute of Technology, Harbin 150001, P.R. China

Q. Chen

Department of Mechanical Engineering, Tsinghua University, Beijing 100084, P. R. China

J. Manuf. Sci. Eng 125(3), 493-503 (Jul 23, 2003) (11 pages) doi:10.1115/1.1556400 History: Received October 01, 2001; Revised July 01, 2002; Online July 23, 2003
Copyright © 2003 by ASME
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Experimental system for monitoring pulsed GTAW with wire filler
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Definitions for different types of weld pool surfaces. (a)—Concave type; (b)—convex type.
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Weld pool images with different imaging currents. (a)—60A, concave; (b)—50A, concave; (c)—40A, concave; (d)—30A, concave; (e)—60A, convex; (f)—50A, convex; (g)—40A, convex; (h)—30A, convex.
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Shape parameter definitions for double-sided weld pool. (a)—Topside; (b)—backside.
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Simulation of the weld pool shape variation during ignition of the pulsed GTAW
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Height parameter definitions for the topside weld pool. (a)—Concave surface; (b)—convex surface.
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Flowchart for the two-dimensional image processing of the topside pool image
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Generalize reflection geometry model
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Triangulation of image plane
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Perspective projection of camera on a triangle surface patch
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Flowchart for calculating surface height
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Synthetic images of a hybrid surface. (a)—xs=60 mm,ys=0 mm,zs=0 mm; (b)—xs=−30 mm,ys=−52 mm,zs=0 mm; (c)—xs=−30 mm,ys=52 mm,zs=0 mm.
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Calculation results of surface height for hybrid surface. (a)—with stereo images, (b)—with a single image.
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Surface height results from a single synthetic image with the improved algorithm. (a)—With smoothing constraint; (b)—With smoothing constraint and boundary conditions; (c)—With smoothing constraint, boundary conditions, and grayness-weighting factor.
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The central height of the object surface from a single image by kinds of algorithms
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Surface height results from a single synthetic image in different coordinate systems: (a)—synthetic image; (b)—in the camera coordinate system; (c)—in the workpiece coordinate system.
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Weld pool images with different wire feed speeds during pulsed GTAW with wire filler. (a)—Vf=6.0 mm/s, (b)—Vf=2.0 mm/s.
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Reconstructed surface height results from single weld pool image. (a)—Vf=6.0 mm/s; (b)—Vf=2.0 mm/s.
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Reconstructed weld pool surface height along axes under wire feed speed 6.0 mm/s and 2.0 mm/s. (a)—Along x-axis, (b)—along y-axis.




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