Monitoring Welding Torch Position and Posture Using Reversed Electrode Images – Part II, Experimental and Analysis for the REI-TPA Model

Abstract

This paper is a sequel to the previous paper. In the previous research (Ref. 1), a REI-TPA model was established to quantitively relate reversed electrode images (REIs) to welding torch position and attitude (TPA). In this research, the REI-TPA model was validated with bead-on-plate welding experiments on S304 stainless steel plates. The contours of the REI and electrode as well as the weld pool geometry were extracted from the image with a developed, robust algorithm, and the arc length was calculated with welding voltage. The offset distance and deflection angle of the welding torch relative to the correct position and attitude were calculated by inputting the extracted parameters into the REI-TPA model. The computational result was compared to the experimental data. The result showed that the model is correct and the monitoring of the welding torch with the REI-TPA model is available. The REI- TPA model can be applied to real-time control of TPA, which is a supplement to the application of the weld passive visual image and an extension of multi- information acquisition and processing methods in the welding process.