Abstract

This paper presents an autonomous augmented reality (AR) projection system developed for weld seam inspection and guidance in industrial applications. The system integrates depth-based contour detection, automatic focus adjustment using Michelson contrast, and keystone correction via AR University of Córdoba Marker (ArUco) homography into a unified self-calibrating pipeline. Implemented on an embedded hardware platform with a multi-threaded software architecture and a web-based interface, the system operates in real time without the need for manual recalibration. Experimental evaluations demonstrated that the system-maintained projection accuracy within sub-millimeter visual tolerance and delivered stable focus performance across varying projection depths. Edge reproduction deviation (ERD) analysis and comparative studies confirmed that depth filtering, homography correction, and spline interpolation significantly enhanced overlay fidelity, while ambient illumination and surface finish introduced minor but manageable variations in clarity. Two case studies validated the system under realistic industrial conditions: weld-path projection on stainless-steel trays achieved a mean absolute error of 0.7 mm with 93% of samples within a 2 mm band, and structured-light projection on perpendicular joints enabled three-dimensional (3D) weld-seam reconstruction and reliable classification of subtle curvature differences between visually similar workpieces. These results confirm that the proposed system provides a robust, contactless, and self-calibrating solution for projection-assisted inspection, demonstrating strong potential for deployment in flexible manufacturing environments.

Keywords

Augmented reality (AR), Weld seam inspection, Depth-based contour detection, Keystone correction, Embedded vision systems, Projection-assisted manufacturing.

Cite this article

Kemthong T, Kangsathien T, Satapanakul D, Chaiprabha K, Chancharoen R, Phanomchoeng G. Autonomous augmented reality projection system for industrial weld seam inspection. International Journal of Advanced Technology and Engineering Exploration. 2025;12(132):1624-1645. DOI : 10.19101/IJATEE.2025.121220738

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