A Real-Time Monitoring Method for Droplet Transfer Frequency in Wire-Filled GTAW Based on Arc Sensing

• Published in: Sensors (Basel, Switzerland) Vol. 24; no. 6; p. 1924
• Main Authors: Jia, Aiting, Luo, Yifang, Hong, Bo, Li, Xiangwen, Yin, Li, Luo, Mina
• Format: Journal Article
• Language: English
• Published: Switzerland MDPI AG 17.03.2024; MDPI
• Subjects: Accuracy; Additive manufacturing; Algorithms; arc sensing; Cameras; Deep learning; droplet transfer; GTAW; Methods; Monitoring systems; Real time; Sensors; Time series; uniformity of droplet transition; Wavelet transforms; Welding; droplet transfer; GTAW; uniformity of droplet transition; arc sensing
• ISSN: 1424-8220; 1424-8220
• DOI: 10.3390/s24061924

Droplet transfer frequency is a decisive factor in welding quality and efficiency in gas tungsten arc welding (GTAW). However, there still needs to be a monitoring method for droplet transfer frequency with high precision and good real-time performance. Therefore, a real-time monitoring method for droplet transfer frequency in wire-filled GTAW using arc sensing is proposed in this paper. An arc signal acquisition system is developed, and the wavelet filtering method filters out noise from the arc signal. An arc signal segmentation method-based on the OTSU algorithm and a feature extraction method for droplet transition based on density-based spatial clustering of applications with noise (DBSCAN)-is proposed to extract the feature signal of the droplet transition. A new conception of droplet transition uniformity is proposed, and it can be used to monitor the weld bead width uniformity. Numerous experiments for monitoring droplet transfer frequency in real time are conducted with typical welding parameters. This method enables the real-time observation of droplet transfer frequency, and the result shows that the average monitoring error is less than 0.05 Hz.