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基于改进CenterNet的铜/铝超声波焊接表面裂纹检测

Surface crack detection in Cu/Al ultrasonic welding based on improved CenterNet

  • 摘要: 薄板金属超声波焊接产生的微细裂纹严重影响焊接质量,以铜/铝超声波焊接接头作为对象,提出一种改进的CenterNet网络应用于超声焊接裂纹检测.将无锚框的CenterNet网络FFM(feature fusion module)模块组成改进的网络,全过程嵌入训练与检测的流程.通过图像处理技术结合数据增强生成数据集和模板样本,采用FLANN(fast libraryfor approximate nearest neighbors)加速的ORB(Oriented FAST and Rotated BRIEF)模板匹配算法定位表面焊接区域,利用改进网络的特征融合模块完成微细焊接裂纹检测,最后通过对比特征融合消融试验和改进网络的检测指标验证了焊接裂纹检测效果.结果表明,采用的模板匹配算法定位焊头压痕区准确度达到95%,改进CenterNet网络用于铜/铝超声波焊接裂纹检测准确率为93%,检测速度达到33.13帧/s,相比于消融试验分别提升了24.0%和63.2%,裂纹检测网络的总参数量为3.04 M,属于轻量级网络.

     

    Abstract: Micro-cracks generated during ultrasonic welding of thin sheet metal seriously affect the welding quality. By taking Cu/Al ultrasonic welded joints as objects, an improved CenterNet network was proposed and applied to ultrasonic welding crack detection. An improved network was formed by an anchor-free CenterNet network and an FFM module and was embedded into the entire process of training and detection. A dataset and template samples were generated through image processing technology combined with data augmentation. A FLANN-accelerated ORB template matching algorithm was adopted to locate the surface welding region. The feature fusion module of the improved network was utilized to complete the detection of fine welding cracks. Finally, the welding crack detection effect was verified by comparing the detection indicators of the feature fusion ablation experiment and the improved network. The results indicate that the accuracy of the adopted template matching algorithm in locating the welding head indentation region reaches 95%. The accuracy of the improved CenterNet network for Cu/Al ultrasonic welding crack detection is 93%, and the detection speed reaches 33.13 frames/s, which are increased by 24.0% and 63.2% respectively compared with the ablation experiment. The total parameter quantity of the crack detection network is 3.04 M, which classifies it as a lightweight network.

     

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