A novel weld seam detection method for space weld seam of narrow butt joint in laser welding

• Published in: Optics and laser technology 2018-02, Vol.99, p.39-51
• Main Authors: Shao, Wen Jun, Huang, Yu, Zhang, Yong
• Format: Article
• Language: English
• Subjects: Butt joint; Butt joints; Butt welding; Deformation; Laser beam welding; Laser welding; Light; Measurement; Metal plates; Misalignment; Seam detection; Structure light; Triangulation; Vision sensor; Welding
• ISSN: 0030-3992; 1879-2545
• DOI: 10.1016/j.optlastec.2017.09.037

•The proposed vision sensor uses three laser stripes with different wave length.•The advantages of active light vision and passive light vision are combined.•Butt joint with no misalignment and width less than 0.1 mm can be measured.•Seam width, seam center and normal vector can be obtained in a single image. Structured light measurement is widely used for weld seam detection owing to its high measurement precision and robust. However, there is nearly no geometrical deformation of the stripe projected onto weld face, whose seam width is less than 0.1 mm and without misalignment. So, it’s very difficult to ensure an exact retrieval of the seam feature. This issue is raised as laser welding for butt joint of thin metal plate is widely applied. Moreover, measurement for the seam width, seam center and the normal vector of the weld face at the same time during welding process is of great importance to the welding quality but rarely reported. Consequently, a seam measurement method based on vision sensor for space weld seam of narrow butt joint is proposed in this article. Three laser stripes with different wave length are project on the weldment, in which two red laser stripes are designed and used to measure the three dimensional profile of the weld face by the principle of optical triangulation, and the third green laser stripe is used as light source to measure the edge and the centerline of the seam by the principle of passive vision sensor. The corresponding image process algorithm is proposed to extract the centerline of the red laser stripes as well as the seam feature. All these three laser stripes are captured and processed in a single image so that the three dimensional position of the space weld seam can be obtained simultaneously. Finally, the result of experiment reveals that the proposed method can meet the precision demand of space narrow butt joint.