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Sensor automated frontface weldbead area control

The development of a vision based sensor for measuring, in real time, the size of the weld bead at the top face during automated welding is described. The technique involves the periodic interruption of the arc for a short time duration ( approximately 3 ms), during which an image of the weld pool is captured by a CCD camera. Analysis of the captured image by hardware techniques gives the size of the bead during the time period before the next image is captured. The sensor has been used to control the bead size of a pulsed TIG weld. A desired bead size is requested and control of the weld bead size is achieved by either modifying the magnitude of the arc current or the duration of the time of the arc pulse of the arc current.