Detection of HF-ERW Process by 3D Bead Shape Measurement With Line-Structured Laser Vision

At present, the High Frequency Electric Resistance Welding(HF-ERW) has been applied in many important industrial fields, whose quality problem has been paid much more attention. The HF-ERW quality is related to the surface burr morphology, however, the traditional weld detection equipment can't detect the HF-ERW morphology well, which seriously affects the HF-ERW quality. In order to realize the real-time detection of HF-ERW quality and optimize the process parameters in welding process, this article primarily discusses the process test of the HF-ERW bead from the parameters of 3D solder bead shape derived from linear laser visual sensor. Firstly, a 3D survey model is established to obtain the 3D welding bead shape based on the mapping between world coordinates and image coordinate systems. Then the weld bead dimensions are calculated from the 3D welding bead shape and analysed to get the correlation to the quality of welding bead. The application system of the sensor for the HF-ERW bead is also set up for experiment. The results of experiments prove that the method can accurately measure the shapes of the 3D and 2D geometries in real-time and the parameters can be used to classify the quality status of HF-ERW process.