Efficiently detecting target weld seams while ensuring sub-millimeter accuracy has always been an important challenge in autonomous welding, which has significant application in industrial practice. Previous works mostly focused on recognizing and localizing welding seams one by one, leading to inferior efficiency in modeling the workpiece. This paper proposes a novel framework capable of multiple weld seams extraction using both RGB images and 3D point clouds. The RGB image is used to obtain the region of interest by approximately localizing the weld seams, and the point cloud is used to achieve the fine-edge extraction of the weld seams within the region of interest using region growth. Our method is further accelerated by using a pre-trained deep learning model to ensure both efficiency and generalization ability. The performance of the proposed method has been comprehensively tested on various workpieces featuring both linear and curved weld seams and in physical experiment systems. The results showcase considerable potential for real-world industrial applications, emphasizing the method's efficiency and effectiveness. Videos of the real-world experiments can be found at https://youtu.be/pq162HSP2D4.

The visual sensing system is one of the most important parts of the welding robots to realize intelligent and autonomous welding. The active visual sensing methods have been widely adopted in robotic welding because of their higher accuracies compared to the passive visual sensing methods. In this paper, we give a comprehensive review of the active visual sensing methods for robotic welding. According to their uses, we divide the state-of-the-art active visual sensing methods into four categories: seam tracking, weld bead defect detection, 3D weld pool geometry measurement and welding path planning. Firstly, we review the principles of these active visual sensing methods. Then, we give a tutorial of the 3D calibration methods for the active visual sensing systems used in intelligent welding robots to fill the gaps in the related fields. At last, we compare the reviewed active visual sensing methods and give the prospects based on their advantages and disadvantages.