Multi-layer/multi-pass welding (MLMPW) technology is widely used in the energy industry to join thick components. During automatic welding using robots or other actuators, it is very important to recognize the actual weld pass position using visual methods, which can then be used not only to perform reasonable path planning for actuators, but also to correct any deviations between the welding torch and the weld pass position in real time. However, due to the small geometrical differences between adjacent weld passes, existing weld position recognition technologies such as structured light methods are not suitable for weld position detection in MLMPW. This paper proposes a novel method for weld position detection, which fuses various kinds of information in MLMPW. First, a synchronous acquisition method is developed to obtain various kinds of visual information when directional light and structured light sources are on, respectively. Then, interferences are eliminated by fusing adjacent images. Finally, the information from directional and structured light images is fused to obtain the 3D positions of the weld passes. Experiment results show that each process can be done in 30 ms and the deviation is less than 0.6 mm. The proposed method can be used for automatic path planning and seam tracking in the robotic MLMPW process as well as electron beam freeform fabrication process.
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