Visualization of welding phenomena and construction of an online control system.
Monozukuri (Saitama University Research Seed Collection 2025-27 p.51)
Keywords: Sensing and visualization of welding phenomena, image processing, AI, deep learning, control, resistance welding simulation, IoT, PLC control.
To visualize the welding phenomenon and achieve high-quality welding, we use visual sensors (CMOS cameras) to capture the welding process, which is then processed through image processing to analyze the phenomenon. We have successfully visualized welding phenomena that are difficult to see due to intense arc light by establishing appropriate imaging techniques. Furthermore, by utilizing AI technology (deep learning), we identify the welding state and control it to achieve good welding results. We are working on building real-time control technology that can be implemented without incurring high costs. In resistance welding, the welding occurs instantaneously, making it difficult to estimate the internal state. Therefore, we conduct numerical simulations using the finite element method (FEM) to realize optimal welding conditions and visualize and analyze complex welding phenomena. We are also actively working to expand the technologies developed for online control of welding phenomena to other fields, enabling us to address challenges not only in welding but also in robot control, IoT, and AI.
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basic information
Professor Satoshi Yamane Graduate School of Science and Engineering, Department of Mathematical and Electronic Information, Field of Electrical and Electronic Physics 【Recent Research Themes】 ●Magnetic Welding Skill Support System ●Visual Robot Welding System ●Estimation and Control of Welding Melting State ●Application of Deep Learning to Robot Welding ●Analysis of Spot Welding Phenomena Using Finite Element Method (FEM)
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Applications/Examples of results
【Appeal Points to the Industry】 ● Visualization technology for welding using CMOS cameras and other tools ● Image processing technology ● Understanding welding phenomena through numerical simulations ● Control system development ● IoT implementation 【Examples of Practical Applications and Utilization】 ● Development of an optimal welding control system through visualization of welding conditions ● Visualization and analysis of difficult-to-measure short-time resistance welding phenomena through simulation ● Measurement and simulation analysis of electromagnetic fields generated by equipment ● Technology transfer system for skilled welders ● Development of a monitoring system for measurement data (IoT)
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Example of weld line detection
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The Saitama University Open Innovation Center is a center that functions as a liaison office for industry-academia-government collaboration. It consists of three departments: the Industry-Academia-Government Collaboration Department, the Intellectual Property Department, and the Startup Support Department, each staffed with coordinators well-versed in various fields. The center's activities include solving technical challenges in companies, supporting the implementation of joint research, and conducting technology transfer aimed at introducing and utilizing Saitama University's intellectual property.
