Real-time seam tracking control system based on line laser visions

Abstract A set of six-degree-of-freedom robotic welding automatic tracking platform was designed in this study to realize the real-time tracking of weld seams. Moreover, the feature point tracking method and the adaptive fuzzy control algorithm in the welding process were studied and analyzed. A laser vision sensor and its measuring principle were designed and studied, respectively. Before welding, the initial coordinate values of the feature points were obtained using morphological methods. After welding, the target tracking method based on Gaussian kernel was used to extract the real-time feature points of the weld. An adaptive fuzzy controller was designed to input the deviation value of the feature points and the change rate of the deviation into the controller. The quantization factors, scale factor, and weight function were adjusted in real time. The input and output domains, fuzzy rules, and membership functions were constantly updated to generate a series of smooth bias robot voltage. Three groups of experiments were conducted on different types of curve welds in a strong arc and splash noise environment using the welding current of 120 A short-circuit Metal Active Gas (MAG) Arc Welding. The tracking error was less than 0.32 mm and the sensor’s metrical frequency can be up to 20 Hz. The end of the torch run smooth during welding. Weld trajectory can be tracked accurately, thereby satisfying the requirements of welding applications.