A novel method: YOLO-CE and 3D point cloud-based feature extraction for welding seams of tower bases

Abstract Robotic automated welding of non-standard steel structures presents significant challenges, particularly for electric power tower bases. This study introduces a novel approach that integrates the You Only Look Once—Compact Invert Block and Efficient Local Attention (YOLO-CE) model, an enhanced version of YOLOV8 for 2D image segmentation, with 3D point cloud technology. The YOLO-CE model is used to accurately extract point cloud data from the target area, which is then processed using the MSAC algorithm for efficient plane segmentation. Weld lines are identified through plane equations, allowing for initial weld point cloud extraction. To further refine accuracy, an optimized evaluation equation is developed that accounts for both the distance between the weld point cloud and the fitted plane, and the angle between their normal vectors. This enables precise classification of the weld point cloud. From this classification, key weld feature points are identified, and their exact positions are determined by calculating the distances between these points and their intersections with three planes. The reliability of the proposed method was validated using a robot for precise measurements, with a total error margin of less than 1.5084 mm, demonstrating high accuracy and stability. Post-operation inspections confirmed that the welds were filled and free from defects, meeting all process requirements. The YOLO-CE model achieved a mIoU of 96.38% and a precision of 99.8%, highlighting its effectiveness. This method provides an efficient and precise solution for the automated welding of non-standard steel structural components and has promising application potential.