A novel single-camera-based vision system for real-time measurement of bead width and height during wire arc additive manufacturing

A novel single-camera-based vision system is developed for real-time measurement of bead dimensions of multilayered deposits during wire arc additive manufacturing (WAAM). Bead widths were detected during deposition using image processing algorithms, while heights were estimated from the widths by fitting the bead cross-section area with curve equations. The measurements obtained from the vision system were compared against the measured deposit dimensions. The vision system detected bead widths with an average error of 5.65%. Fitting the bead cross-sections with a semi-elliptic curve profile gave an accurate estimation of the bead heights, with an average error in height measurement of 9.78%. The vision system was then employed to analyze the effect of deposition strategies on the bead dimensions of thin-walled cylinders. The system accurately captured the bead height variation arising from different deposition strategies. These results demonstrate the system's effectiveness in monitoring thin-walled WAAM depositions.