Accurate weld seam recognition is essential in automated welding systems, as it directly affects path planning and welding quality. With the rapid advancement of industrial vision, weld seam instance segmentation has emerged as a prominent research focus in both academia and industry. However, existing approaches still face significant challenges in boundary perception and structural representation. Due to the inherently elongated shapes, complex geometries, and blurred edges of weld seams, current segmentation models often struggle to maintain high accuracy in practical applications. To address this issue, a novel structure-aware and boundary-enhanced YOLO (SABE-YOLO) is proposed for weld seam instance segmentation. First, a Structure-Aware Fusion Module (SAFM) is designed to enhance structural feature representation through strip pooling attention and element-wise multiplicative fusion, targeting the difficulty in extracting elongated and complex features. Second, a C2f-based Boundary-Enhanced Aggregation Module (C2f-BEAM) is constructed to improve edge feature sensitivity by integrating multi-scale boundary detail extraction, feature aggregation, and attention mechanisms. Finally, the inner minimum point distance-based intersection over union (Inner-MPDIoU) is introduced to improve localization accuracy for weld seam regions. Experimental results on the self-built weld seam image dataset show that SABE-YOLO outperforms YOLOv8n-Seg by 3 percentage points in the AP(50–95) metric, reaching 46.3%. Meanwhile, it maintains a low computational cost (18.3 GFLOPs) and a small number of parameters (6.6M), while achieving an inference speed of 127 FPS, demonstrating a favorable trade-off between segmentation accuracy and computational efficiency. The proposed method provides an effective solution for high-precision visual perception of complex weld seam structures and demonstrates strong potential for industrial application.

Varistors are critical overvoltage protection components in modern power electronic systems. They effectively absorb and dissipate surge energy to ensure the safe and stable operation of electrical equipment. However, surface defects can lead to substandard performance or even trigger equipment failure, compromising overall system stability. Therefore, high-precision surface defect detection is essential for quality assurance. To address these challenges, we propose a lightweight model termed Defect-Aware and Edge-Reconstruction Enhanced YOLO (DAER-YOLO) for efficient varistor inspection. First, we construct a C3k2-based defect-aware enhancement module (C3k2-iEMA). This module tackles the difficulty of extracting features from small or morphologically complex defects. By integrating multi-scale feature extraction, an attention mechanism, and efficient nonlinear mapping, it strengthens the perception of defect details. Second, to enhance the reconstruction capability for edge damage and small-object defects, we introduce the Efficient Up-Convolution Block (EUCB). This block improves multi-level feature fusion and generates clearer enhanced feature maps. Based on these improvements, DAER-YOLO outperforms the YOLOv11n baseline on a custom varistor dataset, with mAP@50 and mAP@50:95 increasing by 1.6% and 2.3%, respectively. Experimental results demonstrate that the model effectively improves detection accuracy while exhibiting significant potential for real-time industrial applications.