Real-Time Image Processing for Monitoring of Free Weld Pool Surface

R. Kovacevic, Y. M. Zhang

Research output: Contribution to journalArticlepeer-review

128 Scopus citations


The are weld pool is always deformed by plasma jet. In a previous study, a novel sensing mechanism was proposed to sense the free weld pool surface. The specular reflection of pulsed laser stripes from the mirror-like pool surface was captured by a CCD camera. The distorted laser stripes clearly depicted the 3D shape of the free pool surface. To monitor and control the welding process, the on-line acquisition of the reflection pattern is required. In this work, the captured image is analyzed to identify the torch and electrode. The weld pool edges are then detected. Because of the interference of the torch and electrode, the acquired pool boundary may be incomplete. To acquire the complete pool boundary, models have been fitted using the edge points. Finally, the stripes reflected from the weld pool are detected. Currently, the reflection pattern and pool boundary are being related to the weld penetration and used to control the weld penetration.

Original languageEnglish
Pages (from-to)161-169
Number of pages9
JournalJournal of Manufacturing Science and Engineering, Transactions of the ASME
Issue number2
StatePublished - May 1997

ASJC Scopus subject areas

  • Control and Systems Engineering
  • Mechanical Engineering
  • Computer Science Applications
  • Industrial and Manufacturing Engineering


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