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基于熔池动态形变知识增强的GTAW熔透状态预测

Prediction of GTAW penetration state based on enhanced knowledge of dynamic morphology molten pool

  • 摘要: 为了实现对焊接熔透状态的在线监测,保障焊缝质量并推动机器人智能化技术发展,提出了一种熔池动态形变知识增强的钨极惰性气体保护焊(gas tungsten arc welding, GTAW)熔透状态预测方法. 采用高速高动态范围工业相机获取熔池图像,利用DeepLabv3 + 语义分割模型进行熔池动态分割以获取精准的熔池区域,在此基础上进行多帧熔池轮廓图像融合,以描述熔池在焊接过程中的动态形变. 将融合后熔池轮廓图像和原始熔池图像合成输入CNN,学习同一位置熔池轮廓像素变化,指导CNN预测熔透状态. 结果表明,基于熔池动态形变知识增强的CNN能够准确识别部分熔透、适度熔透和过度熔透三种典型焊缝状态,分类准确率可达到97.1%,单帧预测时间0.86 ms. 与未融合熔池动态形变特征专家知识的深度学习方法相比,该方法在少样本数据情况下表现出更高的鲁棒性和准确率.

     

    Abstract: To achieve online monitoring of welding penetration status, ensure weld quality, and promote the development of robotic intelligent technology, a knowledge-enhanced prediction method for Gas Tungsten Arc Welding (GTAW) penetration status based on molten pool dynamic deformation is proposed. High-speed, high-dynamic-range industrial cameras are employed to capture molten pool images, and the DeepLabv3 + semantic segmentation model is utilized for dynamic segmentation of the molten pool to obtain precise molten pool regions. On this basis, multi-frame molten pool contour image fusion is performed to describe the dynamic deformation of the molten pool during the welding process. The fused molten pool contour images and original molten pool images are combined and input into a CNN to learn pixel-level changes in the molten pool contours at the same location, guiding the CNN to predict penetration status. Experimental results demonstrate that the CNN enhanced with molten pool dynamic deformation knowledge can accurately identify three typical weld states: partial penetration, adequate penetration, and excessive penetration, achieving a classification accuracy of 97.1% with a single-frame prediction time of 0.86 ms. Compared to deep learning methods without the integration of expert knowledge on molten pool dynamic deformation features, this method exhibits higher robustness and accuracy in scenarios with limited sample data.

     

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