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基于区域生长分割融合深度学习的多层多道焊缝特征提取与分析

Feature extraction and identification of multi-layer multi-pass welds based on region growing segmentation combined with deep learning

  • 摘要: 针对基于结构光视觉传感的焊缝特征提取,以解决中厚板多层多道自动化焊接中存在的激光条纹亮度不均匀、局部高反光、噪声严重、焊缝轮廓特征复杂多变等突出难题,提出一种分块区域生长图像分割融合YOLOv8深度学习算法的焊缝特征提取策略. 组建了单条纹激光 + 高分辨摄像机的视觉传感系统,采集细丝埋弧多层多道焊缝图像,并对每层焊缝图像进行自适应阈值分块区域生长分割、卷积滤波和分段拟合处理,提取每层焊缝特征点. 利用YOLOv8算法提取焊缝图像目标区域特征点像素坐标,构建规划机器人焊接路径. 结果表明,自适应阈值分块区域生长分割算法能够完整提取出激光条纹图像和多层焊道特征点. 深度学习模型总体均方根误差(RMSE)为0.055 1 mm,特征点识别准确率为98.41%,算法精度和鲁棒性较高,能够满足焊缝检测要求,通过焊接试验证实,采用该算法能够获得成形良好的多层多道焊缝形貌,为中厚板多层多道焊接的焊缝检测提供了一种创新的解决方法.

     

    Abstract: To address the significant challenges associated with the multi-layer, multi-pass automated welding of medium-thick plate, including uneven laser stripe brightness, local high reflection, serious noise, and complex and variable weld contour features, we propose an adaptive thresholding chunked-area growth segmentation combined with the YOLOv8 deep learning algorithm for weld seam feature extraction. A single-stripe laser and high-resolution camera are utilized to collect multi-layer, multi-pass weld images of fine wire submerged arc. Adaptive thresholding chunked area growth segmentation, convolutional filtering, and segment fitting are then applied to each layer of weld images to extract the weld feature points of each layer. The YOLOv8 algorithm is employed to ascertain the pixel coordinates of the feature points within the designated area of the multi-layer multi-pass weld image, thereby facilitating the construction of the planning robot weld tracking path. The experimental results demonstrate that the adaptive thresholding chunked region growth segmentation algorithm is capable of fully extracting the laser streak image and multi-layer weld seam feature points. After training, the deep learning model achieved a root mean square error (RMSE) of 0.0551 mm and a 98.41% feature point extraction accuracy, The proposed method demonstrates high feature extraction accuracy and robustness, effectively satisfying the requirements of bead identification. It is demonstrated that a well-formed multi-layer and multi-pass weld is obtained by this proposed algorithm, and provides an innovative solution for weld bead identification in multi-layer multi-pass welding of medium-thick plates.

     

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