基于深度学习的弧焊熔池检测方法研究进展

Research progress on deep learning-based arc welding molten pool detection methods

  • 摘要: 熔池是焊接能量输入与凝固成形的直接载体,其几何形态与动态行为直接影响焊缝成形质量。在实际弧焊中,强弧光辐射、飞溅遮挡及工艺参数波动易造成图像过饱和、轮廓缺失和形态突变,使传统阈值分割与人工特征提取方法在复杂工况下适用性受限。近年来,深度学习为熔池检测提供了数据驱动的新途径,能够从大量图像中自动学习熔池形态特征与演化规律,在鲁棒性、泛化能力和跨工况适应性方面较传统方法更具优势,为稳定获取熔池信息提供了重要技术支撑。围绕弧焊过程感知与质量控制需求,该文系统梳理相关研究进展,总结深度学习在熔池几何参量提取、焊接状态识别、动态行为预测、缺陷检测、异常预警及多模态融合等任务中的应用现状,分析不同模型的优势与适用条件,并从数据层、学习层、目标函数层和结构层归纳面向工程应用的训练与优化策略。分析表明,当前深度学习熔池检测仍面临多工况标注数据不足、模型泛化能力有限、实时性与算力资源受限等问题。未来应构建统一评测基准,发展可迁移模型体系,并与焊接过程控制深度融合,以推动弧焊智能化检测与控制技术发展。

     

    Abstract: Molten pool acts as direct carrier of welding energy input and solidification shaping, and its geometric morphology and dynamic behavior play a decisive role in weld formation quality. In practical arc welding, intense arc radiation, spatter occlusion, and fluctuations in process parameters often result in image overexposure, contour loss, and abrupt morphological variations, which limits effectiveness of traditional methods based on threshold segmentation and manually engineered features under complex conditions. In recent years, deep learning has provided a data-driven approach for molten pool detection, enabling automatic learning of morphological features and evolution patterns from large-scale image data. Compared with conventional methods, deep learning models demonstrate superior robustness, generalization capability, and adaptability across varying working conditions, offering important technical support for stable molten pool information acquisition. To meet the demands of arc welding process sensing and quality control, this paper systematically reviews the relevant research progress and summarizes the application status of deep learning in key tasks, including molten pool geometric parameter extraction, welding state recognition, dynamic behavior prediction, defect detection, anomaly warning, and multimodal fusion. In addition, advantages and applicability of different models are analyzed, and training and optimization strategies oriented toward engineering applications are further summarized from four aspects of data, learning paradigm, objective function, and network architecture. The analysis indicates that the current deep learning-based molten pool detection is still constrained by scarcity of labeled data under diverse conditions, insufficient generalization capability, and limitations in real-time performance and computational resources. Looking forward, it is necessary to establish unified evaluation benchmarks, develop transferable model frameworks, and achieve deeper integration with welding process control, thereby promoting the advancement of intelligent sensing and control technologies in arc welding.

     

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