The presented career episode discusses the project “WELDING INSPECTION SYSTEM” carried out while studying for the Bachelor of Science in Industrial Engineering at the University of Philippines located in Diliman, Philippines. The project was conducted to meet the requirements of the curriculum and attain a bachelor’s degree. All the task in the career episode was done as per the guidance given by the “supervisor name” from “start date” to “end date”.
Welding is a procedure that involves the joining of plastics and especially metals. Almost every man-made product may utilize the welding process because of its various advantages. However, it is a very intricate assembling process, and it needs to pass some quality tests for the market application. This quality test involves the vicinity of weld deformities, observing, fitting sensing, and examination methods for the regulation of quality. Various physical activities need to be done during welding. Automated welding can be developed for better quality, cost, and output.
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This project targeted to make an automated welding system that could perform various extra activities and carry out a welding action smoothly. This project also aimed to increase the quality of welding by reducing the defects. The project made utilization of a laser sensor for weld seam and MATLAB for the task of processing the image. This work was followed by the task of welding with the help of the data collected above. Finally, the project minimized the flaws of welding and gave the output result.
The development of the automatic welding system was the main goal. Other goals were:
- To increase the effectiveness of the welding process with the minimization of defects
- To check the consistency of the process with other similar techniques
I worked on the project with the coordination of all of the project members with the development of proper project plans and schedules. I operated the development of the vision sensor with the preparation of the segment’s geometrical plan. I functioned on the task of image processing with the use of MATLAB. I also attained the necessary results with the measurement of the gauge block in the project.
Personal engineering activity
I gained knowledge of an automated welding system and its benefits at the start of the project. I did the literature review on topics like robust sensors, laser-based sensors, image caption with a camera, automated weld seam tracking, and laser line projection. I also learned about the different types of welding processes like laser welding, tig welding, MIG welding, gas welding, and arc welding. I studied the types of defects and the permitted welding class for such defects. I accumulated knowledge related to the laser triangulation-based design of sensor parameters. I learned about the position of the laser weld that needed to be placed over the weld.
I set up the laser sensor and camera to illuminate the weld seam and the camera to get pictures or images of the weld seam. I developed a vision sensor that fused a structured light laser stripe generator, a GigE camera where I injected the CMOS image sensor and an optical channel that I set before the centering lens. I prepared the segment’s geometrical plan by the utilization of CAD programming for geometric detail for the precise gathering of every sensor part. I made sure that only 650.7 nm wavelength reflected light stripe could pass through the optical channel to the place of the image sensor. I mounted the vision sensor in the light of a perpendicularly multipurpose slide over the abundant hub movement framework. I controlled the framework to get development in three dimensions, following the work of weld examining. I exchanged the image obtained with the vision sensor and a personal computer by the application of an Ethernet link.
Next, I did the work of processing the setup and getting the necessary images. I kept the separation distance between the weld and laser diode adequately long to make sure that the projection enclosed the portion of base material and weld. I made sure that the end goal was capable of locating the cross-segment of the material base at the time of picture examination. I utilized the lines cross-section area discourse to the material base as the new source of the forecast. I carried this task of projecting from the weld. I captured the pictures by using the laser line projection camera on the surfaces of the weld and projected them on the plane surface.
I performed the task of image processing through the utilization of MATLAB. I used the image processing toolbox of MATLAB and the image was opened with Imread and harvested the opened picture with the crop to minimize the information. I performed an endeavor for using the edge identification that resulted in a smooth line with the Canny channel. I increased the pixel level and vertical bearer to consolidate the pixels together by utilizing of enlargement device. I handled all the images by using the Sobel channel. I also used Imfill as the apparatus for filling the gaps and made it one article in a dull range. I used the edge as a portion of capacity bare open to evacuate the greater pixel bunches. I also prepared a MATLAB code and performed the MATLAB graphical interface required for the proposed project.
I obtained the result from the necessary measurement of gauge block, which illustrated that items smaller than 0.2 mm in the path of the z-axis were probable to find. I made no use of a filter on the occasion of the test and kept a single threshold. The anticipated laser line tackled the information obtained from the picture until the focuses were accustomed in the framework direction to the y-hub and x-hub. I altered the graphical interface prepared in MATLAB to allow the information that was sent from the scan control. In this way, I completed a welding inspection system for the proposed project.
I faced the issue of difficulties in locating the cross segments of the base material while processing for setup. This difficulty was realized in the process of examining the picture. This difficulty resulted in harsh conditions for the utilization of lines cross area as the new projection root from welding. To solve the issue, I kept the parting distance between the weld and laser diode long enough and made sure that the projection could cover the portion of the base terminal and weld. This solved the issue as I successfully located the cross-segment area of the material base which was used as the new root of the projection.
I encountered the problem of image processing while running through the software MATLAB. The processed image was utilized, opened, and harvested to minimize the information and for edge identification. I performed an endeavor to use the edge identification that resulted in a smooth line with the Canny channel. However, these lines were unrealistic to unite the adjacent items to widen the devices. Therefore, I utilized the enlargement device for growing the level of pixels and for the vertical bearing to consolidate all the pixels together. After that, all the pictures were handled by the Sobel channel solving the issue of unrealistic lines. All the pictures were prepared with the application of the Sobel channel, and there occurred the widening of the apparatus for joining the item parts, hence the issue was solved.
I performed the coding of the software MATLAB and did the MATLAB graphical interface. I altered the graphical interface prepared in MATLAB to allow the information that was sent from the scan CONTROL. I solved the issue of setup processing and image processing by applying the appropriate engineering solution.
I placed the meeting of the team for identifying the field of studies and tasks. From the resulting study, I developed the Gantt chart for the appropriate division of working studies. I had several discussions with the project supervisor to extract lots of information. Along with this, I regularly observed the development and results produced in the analysis. Then I consulted with my supervisor for a better analysis of the produced results. Finally, the approved results were listed, and the report was developed for submission to the department head.
ISO 14732 was applied for the general study of the standards required in the welding system. IEC 61508 was also applied for the use of MATLAB in this project. All of the project tasks were completed with a good awareness of all of the rules and regulations.
This project targeted to make an automated welding system that could perform various extra activities and carry out a welding action smoothly. This project also aimed to increase the quality of welding by reducing the defects.
I completed the project with the design of the appropriate welding system, which was automatic. I focused on the reduction of defects with the use of this system and worked on the improvement of the consistency of work. I made sure that each activity was completed within the deliberated period.
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