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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: Penetration state is a critical indicator for evaluating welding quality, and it is closely related to molten pool morphology. To address the impact of operating condition fluctuations on welding quality, a quality monitoring system for the laser welding process based on molten pool profile point sets was developed. First, a laser welding experimental platform integrating welding processing, coaxial visual monitoring, and edge computing was established. Second, considering operational efficiency, a hybrid algorithm of maximum inter-class variance multi-threshold segmentation and edge detection based on a histogram pyramid was proposed to accurately extract the features of the high-temperature welding region and molten pool profile. Additionally, a multi-level representation mode based on polar coordinates was innovatively adopted to characterize the profile, thereby forming the molten pool profile point set. Finally, a deep convolutional network model VCAS-Net was constructed to achieve highly efficient and highly accurate mapping between the molten pool profile point set and penetration state. The results indicate that the model achieves an identification accuracy of 95.83%, and the processing time for a single image is 13.23 ms, which meets the requirements for high accuracy and real-time monitoring, and is suitable for industrial field applications

     

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