A Real-Time Monitoring Method for Droplet Transfer Frequency in Wire-Filled GTAW Based on Arc Sensing

Droplet transfer frequency is a decisive factor in welding quality and efficiency in gas tungsten arc welding (GTAW). However, there still needs to be a monitoring method for droplet transfer frequency with high precision and good real-time performance. Therefore, a real-time monitoring method for d...

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Bibliographic Details
Published in:Sensors (Basel, Switzerland) Switzerland), 2024-03, Vol.24 (6), p.1924
Main Authors: Jia, Aiting, Luo, Yifang, Hong, Bo, Li, Xiangwen, Yin, Li, Luo, Mina
Format: Article
Language:English
Subjects:
Accuracy
Additive manufacturing
Algorithms
arc sensing
Cameras
Deep learning
droplet transfer
GTAW
Methods
Monitoring systems
Real time
Sensors
Time series
uniformity of droplet transition
Wavelet transforms
Welding
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Summary:Droplet transfer frequency is a decisive factor in welding quality and efficiency in gas tungsten arc welding (GTAW). However, there still needs to be a monitoring method for droplet transfer frequency with high precision and good real-time performance. Therefore, a real-time monitoring method for droplet transfer frequency in wire-filled GTAW using arc sensing is proposed in this paper. An arc signal acquisition system is developed, and the wavelet filtering method filters out noise from the arc signal. An arc signal segmentation method-based on the OTSU algorithm and a feature extraction method for droplet transition based on density-based spatial clustering of applications with noise (DBSCAN)-is proposed to extract the feature signal of the droplet transition. A new conception of droplet transition uniformity is proposed, and it can be used to monitor the weld bead width uniformity. Numerous experiments for monitoring droplet transfer frequency in real time are conducted with typical welding parameters. This method enables the real-time observation of droplet transfer frequency, and the result shows that the average monitoring error is less than 0.05 Hz.
ISSN:1424-8220
1424-8220
DOI:10.3390/s24061924