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基于多模态信息融合的电弧增材制造熔覆层质量预测分析

Analysis of quality prediction for cladding layers in arc additive manufacturing based on multimodal information fusion

  • 摘要: 机器人电弧增材制造(wire arc additive manufacturing,WAAM)沉积过程剧烈且复杂,过程参数波动大,单一传感器信号难以准确反映成形状态,成形质量控制仍面临较大挑战. 针对这一问题,文中搭建了一套集成视觉、电信号及温度图像的多模态监测平台,基于深度学习与图像处理技术提取熔池形态特征,同时采集熔覆过程中的电流、电压及温度分布信息,实现了多源信息特征的同步提取与融合. 通过设计多组增材工艺试验,建立了包含642组样本的多源特征数据集,并基于轻量级梯度提升机(light gradient boosting machine,LightGBM)集成学习方法构建了熔覆层质量预测模型. 结果表明,所提出方法能够有效提升成形质量预测的准确率,其预测模型宏平均准确率达到90.4%,为实现机器人WAAM过程中的质量智能控制提供了有力的技术支撑.

     

    Abstract: The deposition process of robotic wire arc additive manufacturing (WAAM) is intense and complex, and the process parameters fluctuate significantly. It is difficult for a single sensor signal to accurately reflect the forming state, and forming quality control still faces great challenges. To address this problem, a multimodal monitoring platform integrating vision, electrical signals, and temperature images was constructed. Based on deep learning and image processing technologies, the morphological features of the molten pool were extracted, and the distribution information of current, voltage, and temperature during the cladding process was collected, thereby realizing the synchronous extraction and fusion of multi-source information features. By designing multiple groups of additive manufacturing process experiments, a multi-source feature dataset containing 642 groups of samples was established, and a cladding layer quality prediction model was constructed based on the ensemble learning method of light gradient boosting machine (LightGBM). The results indicate that the proposed method can effectively improve the accuracy of forming quality prediction; the macro-average accuracy of the prediction model reaches 90.4%, which provides strong technical support for realizing intelligent quality control in the robotic WAAM process.

     

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