Aluminum Reservoir Welding Surface Defect Detection Method Based on Three-Dimensional Vision

Welding is an important process in the production of aluminum reservoirs for motor vehicles. The welding quality affects product performance. However, rapid and accurate detection of weld surface defects remains a huge challenge in the field of industrial automation. To address this problem, we proposed a 3D vision-based aluminum reservoir welding surface defect detection method. First of all, a scanning system based on laser line scanning camera was constructed to acquire the point cloud data of weld seams on the aluminum reservoir surface. Next, a planar correction algorithm was used to adjust the slope of the contour line according to the slope of the contour line in order to minimize the effect of systematic disturbances when acquiring weld data. Then, the surface features of the weld, including curvature and normal vector direction, were extracted to extract holes, craters, and undercut defects. For better extraction of the defect, a double-aligned template matching method was used to ensure comprehensive extraction and measurement of defect areas. Finally, the detected defects were categorized according to their morphology. Experimental results show that the proposed method using 3D laser scanning data can detect and classify typical welding defects with an accuracy of more than 97.1%. Furthermore, different types of defects, including holes, undercuts, and craters, can also be accurately detected with precision 98.9%.