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A Review on Smart Welding Systems: AI Integration and Sensor-Based Process Optimization

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Abstract

Although welding is an essential production operation, automated welding systems still struggle to produce consistently high-quality welds. Artificial intelligence (AI) and sensor technology developments in recent years have created new opportunities to increase the effectiveness and quality of welding. The state-of-the-art in sensor technologies and AI-based automation for welding operations is reviewed in this study. Numerous sensing techniques, such as force, arc, temperature, vision, infrared, and audio sensors, have been developed to track and manage welding operations in real-time. The development of intelligent welding systems (IWS) and adaptive intelligent welding production has been made possible by the integration of these sensors with cutting-edge information processing technologies, such as machine learning and deep learning. The applications of sensing technologies in welding seam extraction, welding path identification, welding tracking, and quality diagnostics are covered in this study. The research also emphasizes how crucial it is to choose the right neural network topologies and optimize them for particular goals in process monitoring and welding fault identification. Additionally covered is the incorporation of the attention mechanism notion into the information processing of welding sensing. The review concludes that sensing technology’s capacity to imitate the welder’s superior sensory and cognitive abilities is critical to the success of intelligent welding. Existing AI and sensor-integrated welding systems face challenges such as high complexity, cost, and adaptability issues. This review aims to systematically explore how the integration of AI and advanced sensor technologies can overcome existing limitations in automated welding systems. It identifies the most effective sensor-AI combinations for real-time weld monitoring, fault detection, and adaptive process control. These advancements offer practical benefits such as enhanced weld quality, reduced human intervention, and improved efficiency in industrial applications like automotive and aerospace manufacturing.

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