With the increasing power and speed of laser welding, in-process monitoring has become even more crucial to ensure process stability and weld quality. Due to its low cost and installation flexibility, acoustic process monitoring is a promising method and has demonstrated its effectiveness. Although its feasibility has been the focus of existing studies, the temporal resolution of acoustic emissions (AE) has not yet been addressed despite its utmost importance for realizing real-time systems. Aiming to provide a benchmark for further development, this study investigates the relationship between duration and informativeness of AE signals during high-power ($3.5$ $\mathrm{k}$$\mathrm{W}$) and high-speed (12 $\mathrm{m}$/$\min$) laser beam butt welding. Specifically, the informativeness of AE signals is evaluated based on the accuracy of detecting and quantifying joint gaps for various time windows of signals, yielding numerical comparison. The obtained results show that signals can be shortened up to a certain point without sacrificing their informativeness, encouraging the optimization of the signal duration. Our results also suggest that large gaps (>$0.3$$\mathrm{m}$$\mathrm{m}$) induce unique signal characteristics in AE, which are clearly identifiable from 1 $\mathrm{m}$$\mathrm{s}$ signal segments, equivalent to $0.2$$\mathrm{m}$$\mathrm{m}$ weld seam.

This study aimed to explore the feasibility of using airborne acoustic emission in laser beam butt welding for the development of an automated classification system based on neural networks. The focus was on monitoring the formation of joint gaps during the welding process. To simulate various sizes of butt joint gaps, controlled welding experiments were conducted, and the emitted acoustic signals were captured using audible-to-ultrasonic microphones. To implement an automated monitoring system, a method based on short-time Fourier transformation was developed to extract audio features, and a convolutional neural network architecture with data augmentation was utilized. The results demonstrated that this non-destructive and non-invasive approach was highly effective in detecting joint gap formations, achieving an accuracy of 98%. Furthermore, the system exhibited promising potential for the low-latency monitoring of the welding process. The classification accuracy for various gap sizes reached up to 90%, providing valuable insights for characterizing and categorizing joint gaps accurately. Additionally, increasing the quantity of training data with quality annotations could potentially improve the classifier model’s performance further. This suggests that there is room for future enhancements in the study.

This paper investigates the potential of airborne sound analysis in the human hearing range for automatic defect classification in the arc welding process. We propose a novel sensor setup using microphones and perform several recording sessions under different process conditions. The proposed quality monitoring method using convolutional neural networks achieves 80.5% accuracy in detecting deviations in the arc welding process. This confirms the suitability of airborne analysis and leaves room for improvement in future work.

This study aimed to explore the feasibility of using airborne acoustic emission in laser beam butt welding for the development of an automated classification system based on neural networks. The focus was on monitoring the formation of joint gaps during the welding process. To simulate various sizes of butt joint gaps, controlled welding experiments were conducted, and the emitted acoustic signals were captured using audible to ultrasonic microphones. To implement an automated monitoring system, a method based on short-time Fourier transformation was developed to extract audio features, and a convolutional neural network architecture with data augmentation was utilized. The results demonstrated that this non-destructive and non-invasive approach was highly effective in detecting joint gap formations, achieving an accuracy of 98%. Furthermore, the system exhibited promising potential for low latency monitoring of the welding process. The classification accuracy for various gap sizes reached up to 90%, providing valuable insights for characterizing and categorizing joint gaps accurately. Additionally, increasing the quantity of training data with quality annotations could potentially improve the classifier model's performance further. This suggests that there is room for future enhancements in the study.

With increasing power and speed of laser welding, in-process monitoring has become even more crucial to ensure process stability and weld quality. Due to its low cost and installation flexibility, acoustic process monitoring is a promising method and has demonstrated its effectiveness. Since its feasibility has been the focus of existing studies, the temporal resolution of acoustic emissions (AE) has not yet been addressed despite its utmost importance for realizing real-time systems. Aiming to provide a benchmark for further development, this study investigates the relationship between duration and informativeness of AE signals during high power (3.5kW) and high speed (12m/min) laser beam butt welding. Specifically, the informativeness of AE signals is evaluated based on the accuracy of detecting and quantifying joint gaps for various time windows of signals, yielding numerical comparison. The obtained results show that signals can be shortened up to a certain point without sacrificing their informativeness, encouraging to optimize the signal duration. Our results also suggest that large gaps (> 0.3mm) induce unique signal characteristics in AE, which are clearly identifiable from 1 ms signal segments, equivalent to 0.2mm weld seam.

The development of robust acoustic traffic monitoring (ATM) algorithms based on machine learning faces several challenges. The biggest challenge is to collect and annotate large high-quality datasets for algorithm training and evaluation. Such a dataset must reflect a broad variety of vehicle sounds since their emitted acoustic noise patterns depend on a variety of factors such as engine noises at different speeds and road conditions. Additionally, the characteristics of the employed microphones have a strong influence on the data. If microphones with different directionality and frequency responses are used during the model development and the final deployment phase, a data mismatch is caused, which can have a deteriorating effect on the performance of machine learning algorithms. In this paper, the influence of mismatched recording locations and microphone characteristics on the proposed ATM system is investigated. To evaluate these effects, we implement state-of-the-art convolutional neural networks to detect passing vehicles, classify their type, and estimate their speed and direction of movement. The evaluated models perform well on low- and high-quality recordings at different locations when using the same recording device for training and testing. However, the results indicate that microphone mismatch causes several issues, which need to be carefully addressed.