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.
Highlights
IntroductionThe welding torch must be aligned with the groove center to achieve good welding quality
During complex path welding, the welding torch must be aligned with the groove center to achieve good welding quality
We propose a precise and effective visual narrow butt detection method in specular reflection workpiece welding
Summary
The welding torch must be aligned with the groove center to achieve good welding quality. It is necessary to control the motion path of the torch or the workpiece in real time during the whole welding process. The “teaching-playback” and offline programming techniques are widely used in robotic welding. The welding path is recorded beforehand and the robots can move along the recorded path during welding. In the actual welding conditions, the machining errors, assembly errors and thermal deformation will lead to a deviation between the actual and the recorded welding paths. It is critical to develop automatic seam detection technologies to recognize the position of the actual welding path. The deviation between the torch and the workpiece can be corrected automatically [1]
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