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基于熔池轮廓点集的激光焊接熔透状态实时监测

Real-time monitoring of penetration state in laser welding based on molten pool profile point sets

  • 摘要: 熔透状态是评估焊接质量的关键指标,其与熔池形态密切相关.为了应对工况波动对焊接质量的影响,文中开发了一种基于熔池轮廓点集的激光焊接过程质量监测系统.首先,搭建了集焊接加工、同轴视觉监测及边缘计算于一体的激光焊接试验平台.其次,兼顾运行效率,提出一种基于直方图金字塔的最大类间方差多阈值分割与边缘检测混合算法,准确提取焊接高温区及熔池轮廓特征;并创新性地采用基于极坐标的多层次表达方式表征轮廓,形成熔池轮廓点集.最后,构建了深度卷积网络模型VCAS-Net,实现熔池轮廓点集与熔透状态的高效、高精度映射.结果表明,该模型实现了95.83%的识别准确率,单张图像的处理时间为13.23 ms,满足高准确率与实时监测需求,适用于工业现场应用.

     

    Abstract: The molten penetration state is a critical indicator for assessing welding quality and is closely related to the morphology of the molten pool. To address the impact of fluctuating operating conditions on welding quality, this paper establishes a quality monitoring system for the laser welding process based on a set of molten pool profile points. First, a laser welding experimental platform was developed that integrates welding processing, coaxial visual monitoring, and edge computing. Second, to balance operational efficiency, a hybrid algorithm utilizing maximum inter-class variance multi-threshold segmentation based on histogram pyramids and edge detection was developed. This algorithm accurately extracts features from the high-temperature region and the molten pool profile. Additionally, we innovatively employ a multi-level representation based on polar coordinates to characterize the profile, resulting in a set of molten pool profile points. Finally, we developed a deep convolutional network model called VCAS-Net that efficiently and accurately maps molten pool profile point sets to the molten penetration state. The results indicate that this model achieves an identification accuracy of 95.83%, with a processing time of 13.23 ms per image. This performance satisfies the requirements for both high accuracy and real-time monitoring, making it suitable for industrial applications.

     

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