Real-Time Image Processing for Monitoring of Free Weld Pool Surface

[+] Author and Article Information
R. Kovacevic, Y. M. Zhang

Welding Research and Development Laboratory, Center for Robotics and Manufacturing Systems and, Department of Mechanical Engineering, University of Kentucky, Lexington, KY

J. Manuf. Sci. Eng 119(2), 161-169 (May 01, 1997) (9 pages) doi:10.1115/1.2831091 History: Received April 01, 1995; Revised September 01, 1995; Online January 17, 2008


The arc weld pool is always deformed by plasma jet. In a previous study, a novel sensing mechanism was proposed to sense the free weld pool surface. The specular reflection of pulsed laser stripes from the mirror-like pool surface was captured by a CCD camera. The distorted laser stripes clearly depicted the 3D shape of the free pool surface. To monitor and control the welding process, the on-line acquisition of the reflection pattern is required. In this work, the captured image is analyzed to identify the torch and electrode. The weld pool edges are then detected. Because of the interference of the torch and electrode, the acquired pool boundary may be incomplete. To acquire the complete pool boundary, models have been fitted using the edge points. Finally, the stripes reflected from the weld pool are detected. Currently, the reflection pattern and pool boundary are being related to the weld penetration and used to control the weld penetration.

Copyright © 1997 by The American Society of Mechanical Engineers
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