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基于改进CenterNet的铜/铝超声焊表面裂纹检测

Crack detection in Cu/Al ultrasonic welding based on improved CenterNet network

  • 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加速的ORB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实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/秒,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 significantly compromise weld quality. Focusing on Cu/Al ultrasonic welded joints, this study proposes an improved CenterNet for micro-crack detection in ultrasonic welds. An anchor-free CenterNet network incorporating Feature Fusion Modules (FFM) was developed, enabling seamless integration throughout the training and detection pipeline. A dataset and template samples were generated using image processing techniques combined with data augmentation. The FLANN-accelerated ORB template matching algorithm was first employed to locate the surface weld region. Subsequently, the feature fusion capabilities of the improved network were leveraged to detect fine welding cracks. An ablation study on feature fusion was conducted to validate the crack detection effectiveness. Results demonstrate that the adopted template matching algorithm achieves 95% accuracy in locating the sonotrode indentation zone. Compared to the ablation study, the improved CenterNet attained a crack detection accuracy of 93% for Cu/Al ultrasonic welding, representing an improvement of 24.0%. The detection speed reached 33.13 frames per second (fps), an increase of 63.2%. The total parameter count of the crack detection network is 3.04 million, classifying it as a lightweight network.

     

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