Machine-human Cooperative Control of Welding Process

An innovative auxiliary control system is developed to cooperate with an unskilled welder in a manual GTAW in order to obtain a consistent welding performance. In the proposed system, a novel mobile sensing system is developed to non-intrusively monitor a manual GTAW by measuring three-dimensional (3D) weld pool surface. Specifically, a miniature structured-light laser amounted on torch projects a dot matrix pattern on weld pool surface during the process; Reflected by the weld pool surface, the laser pattern is intercepted by and imaged on the helmet glass, and recorded by a compact camera on it. Deformed reflection pattern contains the geometry information of weld pool, thus is utilized to reconstruct its $3$D surface. An innovative image processing algorithm and a reconstruction scheme have been developed for (3D) reconstruction. The real-time spatial relations of the torch and the helmet is formulated during welding. Two miniature wireless inertial measurement units (WIMU) are mounted on the torch and the helmet, respectively, to detect their rotation rates and accelerations. A quaternion based unscented Kalman filter (UKF) has been designed to estimate the helmet/torch orientations based on the data from the WIMUs. The distance between the torch and the helmet is measured using an extra structure-light low power laser pattern. Furthermore, human welder\u27s behavior in welding performance has been studied, e.g., a welder`s adjustments on welding current were modeled as response to characteristic parameters of the three-dimensional weld pool surface. This response model as a controller is implemented both automatic and manual gas tungsten arc welding process to maintain a consistent full penetration

A Layer Decomposition-Recomposition Framework for Neuron Pruning towards Accurate Lightweight Networks

Neuron pruning is an efficient method to compress the network into a slimmer one for reducing the computational cost and storage overhead. Most of state-of-the-art results are obtained in a layer-by-layer optimization mode. It discards the unimportant input neurons and uses the survived ones to reconstruct the output neurons approaching to the original ones in a layer-by-layer manner. However, an unnoticed problem arises that the information loss is accumulated as layer increases since the survived neurons still do not encode the entire information as before. A better alternative is to propagate the entire useful information to reconstruct the pruned layer instead of directly discarding the less important neurons. To this end, we propose a novel Layer Decomposition-Recomposition Framework (LDRF) for neuron pruning, by which each layer's output information is recovered in an embedding space and then propagated to reconstruct the following pruned layers with useful information preserved. We mainly conduct our experiments on ILSVRC-12 benchmark with VGG-16 and ResNet-50. What should be emphasized is that our results before end-to-end fine-tuning are significantly superior owing to the information-preserving property of our proposed framework.With end-to-end fine-tuning, we achieve state-of-the-art results of 5.13x and 3x speed-up with only 0.5% and 0.65% top-5 accuracy drop respectively, which outperform the existing neuron pruning methods.Comment: accepted by AAAI19 as ora

Measurement of Three-Dimensional Welding Torch Orientation for Manual Arc Welding Process

Methods and systems are provided herein for measuring 3D apparatus (e.g., manual tool or tool accessory) orientation. Example implementations use an auto-nulling algorithm that incorporates a quaternion-based unscented Kalman filter. Example implementations use a miniature inertial measurement unit endowed with a tri-axis gyro and a tri-axis accelerometer. The auto-nulling algorithm serves as an in-line calibration procedure to compensate for the gyro drift, which has been verified to significantly improve the estimation accuracy in three-dimensions, especially in the heading estimation