• Proposes a novel NRS-ANFIS method for real-time welding penetration control in GMAW, achieving 87% complete penetration rate without preheating.
• Uses Neighborhood Rough Set to reduce weld pool features to minimal set (tail width WT and tail area coefficient CTS), enhancing model simplicity and anti-interference.
• Integrates visual sensing, line laser distance, and current data as inputs to ANFIS, enabling dynamic adjustment of welding parameters for time-varying gaps.
• Demonstrates uniform backside melting width and consistent weld quality, meeting industrial specifications for structural welds.