Abstract

Welding seam tracking based on online programming is the future trend of intelligent production. However, most of the existing image processing methods have certain limitations in the adaptability, accuracy, and robustness of weld feature point detection. The online welding method of gas metal arc welding (GMAW) based on active vision sensing is studied in this paper. The Steger sub-pixel detection method is used to guarantee the accuracy of feature point extraction, and a self-adaptive search window and self-adaptive slope extraction are proposed on this basis. The self-adaptive window is generated according to the linear information of the weld area, and the scale factor and range threshold constraint are added to realize the real-time detection of the weld feature information. Screening the center pixel of the laser stripe in the self-adaptive window of the current frame by the initial slope or the self-adaptive slope of the previous frame, the linear information of the weld area is obtained. The self-adaptive slope of the current frame is fitted by the random sampling consistency method, and the pixel margin is retained to adapt to the linear detection of different continuous welds. When arc light and other serious interference make it difficult to obtain weld information, a particle filter is used to make the best prediction of the weld position. Finally, the welding robot platform based on laser vision sensing was built to test various continuous welds of the butt weld, fillet weld, and lap weld. Experimental results show that the detection speed is 27 ms, and the accuracy of detection and tracking can respectively reach 0.03 mm and 0.78 mm, which meets the requirements of weld detection and tracking.

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