EP1036856B1 - Quality control during thermal spraying by computer processing of digital images - Google Patents

Quality control during thermal spraying by computer processing of digital images Download PDF

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Publication number
EP1036856B1
EP1036856B1 EP00105043A EP00105043A EP1036856B1 EP 1036856 B1 EP1036856 B1 EP 1036856B1 EP 00105043 A EP00105043 A EP 00105043A EP 00105043 A EP00105043 A EP 00105043A EP 1036856 B1 EP1036856 B1 EP 1036856B1
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Prior art keywords
quality
thermal spraying
data sets
sprayed layer
geometric surface
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German (de)
French (fr)
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EP1036856A1 (en
Inventor
Peter Dipl.-Ing. (Fh) Heinrich
Werner Krömmer
Klaus Prof.Dr. Landes
Jochen Dipl.-Ing. Zierhut
Tilo Dipl.-Phys. Streibl
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Linde GmbH
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Linde GmbH
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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/02—Coating starting from inorganic powder by application of pressure only
    • C23C24/04—Impact or kinetic deposition of particles

Definitions

  • the invention relates to a method for thermal spraying to produce a Spray coating on the surface of a substrate, wherein by means of a digital At least one of the quality of the sprayed layer influencing feature of the thermal spraying process detected, controlled and / or monitored.
  • the invention further relates to a system for quality assurance in the production of a Spray coating on the surface of a substrate by means of a thermal Spray method comprising a digital camera for detection, control and / or Monitoring at least one affecting the quality of the sprayed layer Feature of the thermal spraying process.
  • thermal spraying usually an optionally on or molten filler material using a gas or gas mixture directed to the surface of the substrate to be coated.
  • Such parameters are for example the Gas flows (carrier gas and / or possibly fuel gas), the currents, the Spray distance, the spray angle (angle between spray jet and substrate surface), the relative velocity of the spray jet to the substrate surface, the Introducing the filler material, the amount of spray powder or the wire feed speeds Etc.
  • thermal spraying for coating come in Scope of the invention in principle all known process variants into consideration like the autogenous flame spraying, the high-speed flame spraying, the Plasma spraying, arc spraying, detonation spraying or laser spraying, but also the variant of the thermal called cold gas spraying Spritzens, a kind of advancement of high-speed flame spraying (for example described in European patent EP 0 484 533 B1).
  • cold gas spraying a filler material is used in powder form, wherein the powder particles are not melted in the gas jet during cold gas spraying, but the temperature of the gas jet below the melting point of the filler particles lies.
  • German patent application 198 20 195.8 by detecting, controlling and / or monitoring the quality of the sprayed coating influencing features of the thermal spraying process leads to a In terms of effort relatively simple, but extremely efficient quality assurance for thermal spraying.
  • the reproducibility of sprayed layers based on a rating of quality characteristics or parameters and / or sizes of Spraying process over image standards of this diagnostics ensures and the spray coatings be brought to consistent quality very quickly. It is important that an impairment of the thermal spraying process or damage the sprayed layer by the detection, control and / or monitoring of Quality features due to the purely optical access in any case excluded is.
  • the characteristic of the image in the reflow zone is identical with the earlier one.
  • the capture, control and / or monitoring with the digital camera can be used for Control and, where appropriate, to optimize one or more parameters be used.
  • Digital technology makes it easy to capture Control and / or monitoring the quality of the spray coating serving Records made visible immediately during the current injection process and / or be evaluated and so take place an optimizing control of Spritzparametem can.
  • the optimization of the parameters contributes to the economy of the thermal spraying process, as an inefficiently high consumption of one or several substances required in the thermal spraying process (e.g. Filler materials) can be avoided and thus a saving can be achieved.
  • the present invention is based on the object, the aforementioned method and further develop the aforementioned systems, wherein the arithmetic Revision and / or alienation is further developed and improved. Especially The information underlying the diagnosis should be as extensive as possible kept low or reduced, so that the handling, speed and / or data storage is simplified.
  • the object is achieved with respect to the system by the subject matter of claim 8. They are means to Detection of the symmetric or geometric surface body by means of for the respective geometric form of characteristic features as data set or Records exist using this record or these records the at least one influencing the quality of the sprayed layer feature of thermal spraying process detected, controlled and / or monitored.
  • the symmetry of the geometric sheet comprises within the scope of the invention Axial symmetries and rotational symmetries.
  • the one or more symmetrical geometric Surface body based on characteristic for the respective geometric shape Characteristics recorded as a record or records and via this record or via these datasets that influence at least one quality of the sprayed layer Detected feature of the thermal spraying process, controlled and / or monitored.
  • symmetric geometric surface bodies are in particular circles, Squares, rectangles, parallelograms and / or ellipses used. It will be Ellipses preferably used, since usually arise oval structures due to their similarity in the contour with ellipses easily and relatively accurately are.
  • the mathematical revision and / or alienation is preferred by means of a Contour detection algorithm, by means of a representation in gradient levels and / or carried out by means of a gradient-emphasized, reduced on bit level representation.
  • the at least one influencing the quality of the sprayed layer feature of Thermal spraying process can the spraying process itself and / or the case relate to used spray gun.
  • the symmetrical geometric surface bodies or preferably their datasets can be used to control and if necessary to optimize one or more parameters be used.
  • the symmetrical geometric surface body or prefers their datasets to document one or more the quality of Injection-influencing characteristics and / or the injection process itself be used.
  • the invention ensures the quality assurance of a diagnosis, which on relative (with regard to the large number of parameters during thermal spraying) Low data volumes based on and for the injection process or for the Sprayer is based on meaningful and unambiguous data.
  • the image sequence is an inventive computational revision and / or Based on alienation.
  • the computationally revised or alienated image representation leads to a data record one or more ellipses used for quality assurance purposes Spray process (in the broader sense) both the spray gun and the spray process characterize itself (in the narrower sense).

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Investigating Or Analyzing Materials Using Thermal Means (AREA)

Abstract

Thermal spray coating process comprises computer processing of digital camera images for associating similar intensity regions with symmetrical flat geometrical shapes. A thermal spray coating process uses a digital camera for detecting, controlling and/or monitoring process parameters which affect the sprayed layer quality, the image being computer processed for associating one or more regions of the same intensity and/or within a certain intensity range with one or more symmetrical flat geometrical shapes. An Independent claim is also included for quality control equipment for use in the above process.

Description

Die Erfindung betrifft ein Verfahren zum thermischen Spritzen zur Erzeugung einer Spritzschicht auf der Oberfläche eines Substrates, wobei mittels einer digitalen Kamera zumindest ein die Qualität der Spritzschicht beeinflussendes Merkmal des thermischen Spritzprozesses erfaßt, kontrolliert und/oder überwacht wird. Die Erfindung betrifft ferner eine Anlage zur Qualitätssicherung bei der Erzeugung einer Spritzschicht auf der Oberfläche eines Substrates mittels eines thermischen Spritzverfahrens umfassend eine digitale Kamera zur Erfassung, Kontrolle und/oder Überwachung zumindest eines die Qualität der Spritzschicht beeinflussenden Merkmals des thermischen Spritzprozesses.The invention relates to a method for thermal spraying to produce a Spray coating on the surface of a substrate, wherein by means of a digital At least one of the quality of the sprayed layer influencing feature of the thermal spraying process detected, controlled and / or monitored. The The invention further relates to a system for quality assurance in the production of a Spray coating on the surface of a substrate by means of a thermal Spray method comprising a digital camera for detection, control and / or Monitoring at least one affecting the quality of the sprayed layer Feature of the thermal spraying process.

Bei thermischen Spritzverfahren wird üblicherweise ein gegebenenfalls an- oder aufgeschmolzener Zusatzwerkstoff unter Einsatz eines Gases oder Gasgemisches auf die zu beschichtende Oberfläche des Substrates geleitet.In thermal spraying usually an optionally on or molten filler material using a gas or gas mixture directed to the surface of the substrate to be coated.

Ein Verfahren und eine Anlage der eingangs genannten Art werden in EP-A-0 955 389, veröffentlicht aus 10.11.1999, mit Prioritätsdaten von 06.05.1998 und korrespondierend zu der eigenen deutschen Patentanmeldung 198 20 195.8 beschrieben. Dabei stand als Ausgangspunkt das Bestreben, die Reproduzierbarkeit, die Erfüllung von Qualitätsansprüchen und die Einhaltung vorgegebener Qualitätsanforderungen durch Erfassung, Kontrolle und/oder Überwachung der Einflußparameter beim thermischen Spritzen gewährleisten zu können. Dazu werden relevante Prozeßparameter gemessen, geregelt und gegebenenfalls auch dokumentiert. Derartige Parameter sind beispielsweise die Gasflüsse (Trägergas und/oder gegebenenfalls Brenngas), die Stromstärken, der Spritzabstand, der Spritzwinkel (Winkel zwischen Spritzstrahl und Substratoberfläche), die Relativgeschwindigkeit des Spritzstrahls zur Substratoberfläche, die Einbringung des Zusatzwerkstoffes, die Menge des Spritzpulvers bzw. die Drahtvorschubgeschwindigkeiten etc.A method and an apparatus of the type mentioned in the beginning are described in EP-A-0 955 389, published on 10.11.1999, with priority data of 06.05.1998 and corresponding to the own German Patent Application 198 20 195.8 described. It stood as a starting point the endeavor, the reproducibility, the fulfillment of quality standards and compliance with given quality requirements through registration, control and / or monitoring the influence parameters during thermal spraying to be able to. For this purpose, relevant process parameters are measured, controlled and possibly also documented. Such parameters are for example the Gas flows (carrier gas and / or possibly fuel gas), the currents, the Spray distance, the spray angle (angle between spray jet and substrate surface), the relative velocity of the spray jet to the substrate surface, the Introducing the filler material, the amount of spray powder or the wire feed speeds Etc.

Als Verfahrensvarianten des thermischen Spritzens zum Beschichten kommen im Rahmen der Erfindung grundsätzlich alle bekannten Verfahrensvarianten in Betracht wie das autogene Flammspritzen, das Hochgeschwindigkeits-Flammspritzen, das Plasmaspritzen, das Lichtbogenspritzen, das Detonationsspritzen oder das Laserspritzen, aber auch die als Kaltgasspritzen bezeichnete Variante des thermischen Spritzens, eine Art Weiterentwicklung des Hochgeschwindigkeits-Flammspritzens (beispielsweise in der europäischen Patentschrift EP 0 484 533 B1 beschrieben). Beim Kaltgasspritzen kommt ein Zusatzwerkstoff in Pulverform zum Einsatz, wobei die Pulverpartikel beim Kaltgasspritzen nicht im Gasstrahl geschmolzen werden, sondern die Temperatur des Gasstrahles unterhalb des Schmelzpunktes der Zusatzwerkstoffpulverpartikel liegt.As process variants of thermal spraying for coating come in Scope of the invention in principle all known process variants into consideration like the autogenous flame spraying, the high-speed flame spraying, the Plasma spraying, arc spraying, detonation spraying or laser spraying, but also the variant of the thermal called cold gas spraying Spritzens, a kind of advancement of high-speed flame spraying (for example described in European patent EP 0 484 533 B1). When cold gas spraying a filler material is used in powder form, wherein the powder particles are not melted in the gas jet during cold gas spraying, but the temperature of the gas jet below the melting point of the filler particles lies.

In der Anlage nach der eigenen deutschen Patentanmeldung 198 20 195.8 ist eine digitale Kamera zur Erfassung, Kontrolle und/oder Überwachung zumindest eines die Qualität der Spritzschicht beeinflussenden Merkmals des thermischen Spritzprozesses vorgesehen. Als Digitalkamera können sowohl digitale Bildkameras wie auch digitale Videokameras eingesetzt werden. Es können also einerseits Einzelbilder und/oder als Sequenzen zu einem Film zusammengesetzte Videobilder die geforderte Erfassung, Kontrolle und/oder Überwachung bringen, wobei die Grenze zwischen Einzelbildern auf der einen Seite und Film auf der anderen Seite ohnehin nicht scharf definiert ist, aber als Untergrenze für die Bildfrequenz bei einem Film aufgrund der Trägheit des menschlichen Auges etwa 16 Bilder pro Sekunde betrachtet werden können.In the plant according to the German patent application 198 20 195.8 is a digital camera for capturing, controlling and / or monitoring at least one of Quality of the spray-influencing feature of the thermal spraying process intended. Digital cameras can be digital cameras as well digital video cameras are used. So it can on the one hand individual images and / or video sequences composed as sequences into a movie Capture, control and / or monitor bringing the boundary between Still not sharp on the one hand and the other on the other hand is defined as the lower limit for the frame rate of a movie due to the Inertia of the human eye can be considered about 16 frames per second can.

Die in der eigenen deutschen Patentanmeldung 198 20 195.8 beschriebene Diagnostik durch Erfassung, Kontrolle und/oder Überwachung von die Qualität der Spritzschicht beeinflussenden Merkmalen des thermischen Spritzprozesses führt zu einer vom Aufwand her relativ einfachen, aber außerordentlich effizienten Qualitätssicherung für das thermische Spritzen. So kann beispielsweise in Betrieben, welche das thermische Spritzen einsetzen, gleichzeitig aber häufig wechselnde Spritzanwendungen auftreten, die Reproduzierbarkeit von Spritzschichten anhand einer Bewertung von qualitätsprägenden Merkmalen bzw. von Parametern und/oder Größen des Spritzprozesses über Bildstandards dieser Diagnostik gewährleistet und die Spritzschichten sehr schnell auf gleichbleibende Qualität gebracht werden. Dabei ist wichtig, daß eine Beeinträchtigung des thermischen Spritzprozesses oder eine Beschädigung der Spritzschicht durch die Erfassung, Kontrolle und/oder Überwachung der Qualitätsmerkmale aufgrund des rein optischen Zugangs auf jeden Fall ausgeschlossen ist. Andererseits kann beispielsweise aber auch nach längerer Zeit gewährleistet werden, daß die gleiche Anwendung mit gleicher Spritzqualität gespritzt wird, wenn beispielsweise die Charakteristik des Bildes in der Zone des Aufschmelzens identisch mit der früheren ist.The diagnosis described in German patent application 198 20 195.8 by detecting, controlling and / or monitoring the quality of the sprayed coating influencing features of the thermal spraying process leads to a In terms of effort relatively simple, but extremely efficient quality assurance for thermal spraying. For example, in companies that use the use thermal spraying, but at the same time frequently changing spray applications occur, the reproducibility of sprayed layers based on a rating of quality characteristics or parameters and / or sizes of Spraying process over image standards of this diagnostics ensures and the spray coatings be brought to consistent quality very quickly. It is important that an impairment of the thermal spraying process or damage the sprayed layer by the detection, control and / or monitoring of Quality features due to the purely optical access in any case excluded is. On the other hand, for example, but also guaranteed after a long time be sprayed the same application with the same spray quality, though For example, the characteristic of the image in the reflow zone is identical with the earlier one.

Die Erfassung, Kontrolle und/oder Überwachung mit der digitalen Kamera kann zur Regelung und gegebenenfalls zur Optimierung eines oder mehrerer Parameter verwendet werden. Die Digitaltechnik ermöglicht es problemlos, daß die zur Erfassung, Kontrolle und/oder Überwachung der Qualität der Spritzschicht dienenden Aufzeichnungen unmittelbar im laufenden Spritzprozeß sichtbar gemacht und/oder ausgewertet werden und so eine optimierende Regelung von Spritzparametem stattfinden kann. Die Optimierung der Parameter trägt zur Wirtschaftlichkeit des thermischen Spritzprozesses bei, da ein uneffektiv hoher Verbrauch eines oder mehrerer im thermischen Spritzverfahren benötigter Stoffe (z.B. Gasmengen, Zusatzwerkstoffe) vermieden werden und somit eine Ersparnis erzielt werden kann.The capture, control and / or monitoring with the digital camera can be used for Control and, where appropriate, to optimize one or more parameters be used. Digital technology makes it easy to capture Control and / or monitoring the quality of the spray coating serving Records made visible immediately during the current injection process and / or be evaluated and so take place an optimizing control of Spritzparametem can. The optimization of the parameters contributes to the economy of the thermal spraying process, as an inefficiently high consumption of one or several substances required in the thermal spraying process (e.g. Filler materials) can be avoided and thus a saving can be achieved.

Dabei kann das ganze Vielfalt der Darstellungsmöglichkeiten, welche die Digitaltechnik eröffnet, ausgenutzt werden. Je nach Einzelfall können unterschiedliche Darstellungsvarianten - insbesondere rechnerisch überarbeitete oder verfremdete - bestimmte Vorteile mit sich bringen. Die Darstellung der Bilder oder Videoaufzeichnungen kann dabei grundsätzlich schwarzweiß oder farbig erfolgen, wobei auch Mischformen mit beispielsweise teilweiser farbiger Darstellung möglich sind.Thereby the whole variety of representation possibilities, which the digital technology opened, exploited. Depending on the individual case can be different Representation variants - in particular computationally revised or alienated - certain benefits. The presentation of pictures or video recordings can be done in principle black and white or colored, and also Mixed forms with, for example, partial color representation are possible.

Ein weiteres Verfahren sowie eine Vorrichtung zur Messung und Auswertung eines Partikelsprühmusters mittels einer CCD-Kamera und eines Rechners sind aus der Publikation Lehtinen T. et al. "Correlations between in flight particles concentrations and coating properties in atmospheric plasma spraying of alumina", Proceedings of the 9th National Thermal Spray Conference (NTSC), Cincinnati, US, 7.-11.10.1996, Seiten 525-530, bekannt.Another method and apparatus for measuring and evaluating a Particle spray patterns by means of a CCD camera and a computer are from the publication Lehtinen T. et al. "Correlations between in flight particles and coating properties in atmospheric plasma spraying of alumina", Proceedings of the 9th National Thermal Spray Conference (NTSC), Cincinnati, US, 7.-11.10.1996, pages 525-530, known.

Der vorliegenden Erfindung liegt die Aufgabe zugrunde, die eingangs genannten Verfahren und die eingangs genannten Anlagen weiterzubilden, wobei die rechnerische Überarbeitung und/oder Verfremdung weiterentwickelt und verbessert wird. Insbesondere sollten die der Diagnostik zugrundeliegenden Informationen im Umfang möglichst gering gehalten bzw. reduziert werden, so daß die Handhabung, Schnelligkeit und/oder Datenspeicherung vereinfacht wird.The present invention is based on the object, the aforementioned method and further develop the aforementioned systems, wherein the arithmetic Revision and / or alienation is further developed and improved. Especially The information underlying the diagnosis should be as extensive as possible kept low or reduced, so that the handling, speed and / or data storage is simplified.

Die gestellte Aufgabe wird durch das in Anspruch 1 definierte Verfahren gelöst. In den Bildern wird mittels rechnerischer Überarbeitung und/oder Verfremdung mindestens ein Bereich gleicher Intensität und/oder mindestens ein Bereich innerhalb eines bestimmten Intensitätsintervalls einem oder mehreren symmetrischen geometrischen Flächenkörpern zugeordnet. The stated object is achieved by the method defined in claim 1. In the Images become at least one by means of computational revision and / or alienation Area of equal intensity and / or at least one area within a particular Intensity interval one or more symmetric geometric Assigned to surface bodies.

Die gestellte Aufgabe wird hinsichtlich der Anlage durch den Gegenstand von Anspruch 8 gelöst. Es sind Mittel zur Erfassung des oder der symmetrischen geometrischen Flächenkörper anhand von für die jeweilige geometrische Form charakteristischer Merkmale als Datensatz oder Datensätze vorhanden, wobei über diesen Datensatz oder über diese Datensätze das zumindest eine die Qualität der Spritzschicht beeinflussende Merkmal des thermischen Spritzprozesses erfaßt, kontrolliert und/oder überwacht wird.The object is achieved with respect to the system by the subject matter of claim 8. They are means to Detection of the symmetric or geometric surface body by means of for the respective geometric form of characteristic features as data set or Records exist using this record or these records the at least one influencing the quality of the sprayed layer feature of thermal spraying process detected, controlled and / or monitored.

Bevorzugte Ausführungsformen des Verfahrens und der Anlage sind in den Ansprüchen 2 bis 7 bzw. 9 und 10 definiert.Preferred embodiments of the method and the plant are in the claims 2 to 7 or 9 and 10 defined.

Die Symmetrie der geometrischen Flächenkörper umfaßt im Rahmen der Erfindung Achssymmetrien und Rotationssymmetrien.The symmetry of the geometric sheet comprises within the scope of the invention Axial symmetries and rotational symmetries.

In Ausgestaltung der Erfindung werden der oder die symmetrischen geometrischen Flächenkörper anhand von für die jeweilige geometrische Form charakteristischen Merkmalen als Datensatz oder Datensätze erfaßt und über diesen Datensatz oder über diese Datensätze das zumindest eine die Qualität der Spritzschicht beeinflussende Merkmal des thermischen Spritzprozesses erfaßt, kontrolliert und/oder überwacht.In an embodiment of the invention, the one or more symmetrical geometric Surface body based on characteristic for the respective geometric shape Characteristics recorded as a record or records and via this record or via these datasets that influence at least one quality of the sprayed layer Detected feature of the thermal spraying process, controlled and / or monitored.

Als symmetrische geometrische Flächenkörper werden insbesondere Kreise, Quadrate, Rechtecke, Parallelogramme und/oder Ellipsen eingesetzt. Dabei werden Ellipsen bevorzugt verwendet, da sich in der Regel ovale Gebilde ergeben, die aufgrund ihrer Ähnlichkeit in der Kontur mit Ellipsen leicht und relativ exakt zu erfassen sind.As symmetric geometric surface bodies are in particular circles, Squares, rectangles, parallelograms and / or ellipses used. It will be Ellipses preferably used, since usually arise oval structures due to their similarity in the contour with ellipses easily and relatively accurately are.

Mit Vorteil werden von einander unabhängige charakteristische Merkmale als Datensatz für die jeweilige geometrische Form erfaßt. Dies hilft, die Zahl der Daten einerseits gering zu halten, andererseits aber möglichst aussagekräftige Daten zu ermitteln.Advantageously, independent of each other characteristic features Record detected for the respective geometric shape. This helps the number of dates on the one hand to keep low, but on the other hand as meaningful data to determine.

Die rechnerische Überarbeitung und/oder Verfremdung wird bevorzugt mittels eines Konturerfassungsalgorithmus, mittels einer Darstellung in Gradientenstufen und/oder mittels einer gradientenbetonten, auf Bitebene reduzierten Darstellung durchgeführt.The mathematical revision and / or alienation is preferred by means of a Contour detection algorithm, by means of a representation in gradient levels and / or carried out by means of a gradient-emphasized, reduced on bit level representation.

Das zumindest eine die Qualität der Spritzschicht beeinflussende Merkmal des thermischen Spritzprozesses kann den Spritzprozeß selbst und/oder den dabei benutzten Spritzapparat betreffen. The at least one influencing the quality of the sprayed layer feature of Thermal spraying process can the spraying process itself and / or the case relate to used spray gun.

Die symmetrischen geometrischen Flächenkörper oder bevorzugt deren Datensätze können zur Regelung und gegebenenfalls zur Optimierung eines oder mehrerer Parameter verwendet werden.The symmetrical geometric surface bodies or preferably their datasets can be used to control and if necessary to optimize one or more parameters be used.

Ebenso ist es möglich, daß die symmetrischen geometrischen Flächenkörper oder bevorzugt deren Datensätze zur Dokumentation eines oder mehrerer die Qualität der Spritzschicht beeinflussenden Merkmale und/oder des Spritzprozesses an sich verwendet werden.It is also possible that the symmetrical geometric surface body or prefers their datasets to document one or more the quality of Injection-influencing characteristics and / or the injection process itself be used.

Die Erfindung gewährleistet die Qualitätssicherung über eine Diagnostik, welche auf verhältnismäßig (bezüglich der Vielzahl der Parameter beim thermischen Spritzen) geringen Datenmengen basiert und dabei auf für den Spritzprozeß bzw. für den Spritzapparat aussagekräftige und eindeutige Daten beruht.The invention ensures the quality assurance of a diagnosis, which on relative (with regard to the large number of parameters during thermal spraying) Low data volumes based on and for the injection process or for the Sprayer is based on meaningful and unambiguous data.

Im Hinblick auf den Spritzapparat (Brenner) lassen sich aus den geometrischen Flächenkörpern oder bevorzugt aus deren Datensätzen beispielsweise folgende Aussagen unmittelbar ableiten:

  • am Beispiel des Plasmabrenners (Plasmaspritzen):
    • Zustand der Elektroden,
    • Enthalpieänderungen im Freistrahl und
    • die Enthalpieverteilung im Freistrahl
  • am Beispiel des HVOF-Brenners (Hochgeschwindigkeits-Flammspritzen):
    • Geschwindigkeit des ausströmenden Gases (Abstand der Überschallknoten),
    • Enthalpieänderungen im Freistrahl und
    • die Enthalpieverteilung im Freistrahl.
With regard to the spray gun (burner), for example, the following statements can be derived directly from the geometric surface bodies or preferably from their data sets:
  • using the plasma burner (plasma spraying) as an example:
    • State of the electrodes,
    • Enthalpy changes in the free jet and
    • the enthalpy distribution in the free jet
  • using the example of the HVOF burner (high-speed flame spraying):
    • Velocity of the outflowing gas (distance of supersonic nodes),
    • Enthalpy changes in the free jet and
    • the enthalpy distribution in the free jet.

Aus den geometrischen Flächenkörpern bzw. bevorzugt aus deren Datensätze können für den Spritzprozeß, d.h. den Partikelstrahl, beispielsweise die Merkmale:

  • Aufschmelzverhalten,
  • Apertur,
  • Schwerpunkt und
  • Richtung
erfaßt werden. From the geometric surface bodies or preferably from their datasets, for the injection process, ie the particle beam, for example the features:
  • melting behavior,
  • aperture,
  • Focus and
  • direction
be detected.

Im folgenden soll die Erfindung anhand eines Ausführungsbeispiels näher erläutert werden.In the following, the invention will be explained in more detail with reference to an embodiment become.

Hierbei zeigt:

Figur:
die einzelne Stufen einer erfindungsgemäßen Bildbearbeitung zur Qualitätssicherung beim thermischen Spritzen.
Hereby shows:
Figure :
the individual stages of an image processing according to the invention for quality assurance during thermal spraying.

In der Figur sind die Stufen einer erfindungsgemäßen Bildbearbeitung zur Qualitätssicherung beim thermischen Spritzen - im Ausführungsbeispiel ein Plasmaspritzen - in einer Bilderfolge gezeigt. Die einzelnen Stufen sind dabei:

  • 1. Bildaufzeichnung,
  • 2. Konturerfassung,
  • 3. Ellipseneinpassung,
  • 4. Ellipsenbeschreibung und
  • 5. Datenbank.
    • In the figure , the stages of an inventive image processing for quality assurance during thermal spraying - in the exemplary embodiment, a plasma spraying - shown in a series of images. The individual levels are:
  • 1. image recording,
  • 2. Contour detection,
  • 3. elliptical fitting,
  • 4. Ellipse description and
  • 5. Database.

    • Der Bilderfolge liegt eine erfindungsgemäße rechnerische Überarbeitung und/oder Verfremdung zugrunde.The image sequence is an inventive computational revision and / or Based on alienation.

    Mittels eines Kontur-Erfassungsalgorithmus oder einer Gradientenstufendarstellung oder einer gradientenbetonten, auf Bitebene reduzierten Darstellung werden Bereiche gleicher Intensitäten in den belichteten Bildteilen markiert. Diese sowohl für den Zustand und den Betrieb des Spritzapparates (Brenner) als auch für den Zustand und den Verlauf des Spritzprozesses aussagekräftigen Informationen werden daraufhin als Informationsträger für die weitere Bearbeitung verwendet.By means of a contour detection algorithm or a gradient level representation or a gradient-biased rendering reduced to bit-level become areas marked equal intensities in the exposed image parts. These both for the Condition and operation of the spray gun (burner) as well as the condition and The course of the injection process meaningful information will be thereupon used as information carrier for further processing.

    In den sich ergebenden ovalen Gebilden werden eine oder mehrere Ellipsen eingepaßt. Dabei wird jede Ellipse mittels ihrer fünf unabhängigen Eigenschaften vollständig beschrieben. Diese Eigenschaften sind:

    • vertikale Position des Ellipsenschwerpunktes,
    • horizontale Position des Ellipsenschwerpunktes,
    • Länge der Halbachse 1,
    • Länge der Halbachse 2 und
    • Winkel einer der Halbachsen zur Horizontalen.
    In the resulting oval structures one or more ellipses are fitted. Each ellipse is fully described by its five independent properties. These properties are:
    • vertical position of the ellipse center of gravity,
    • horizontal position of the ellipse center of gravity,
    • Length of the semi-axis 1,
    • Length of the semi-axis 2 and
    • Angle of one of the half-axes to the horizontal.

    Die rechnerisch überarbeitete oder verfremdete Bilddarstellung führt zu einem Datensatz einer oder mehrere Ellipsen, die im Hinblick auf die Qualitätssicherung beim Spritzprozeß (im weiteren Sinne) sowohl den Spritzapparat als auch den Spritzprozeß selbst (im engeren Sinne) charakterisieren.The computationally revised or alienated image representation leads to a data record one or more ellipses used for quality assurance purposes Spray process (in the broader sense) both the spray gun and the spray process characterize itself (in the narrower sense).

    Auf diese Weise läßt sich die Information des gesamten Spritzprozesses auf wenige sehr aussagekräftige, eindeutige Informationen reduzieren, wodurch eine leichte, mathematisch unterstützte Prozeßdiagnostik realisierbar ist.In this way, the information of the entire injection process to a few reduce very meaningful, unambiguous information, creating a light, mathematically supported process diagnostics can be realized.

    Claims (10)

    1. Thermal spraying method for producing a sprayed layer on the surface of a substrate, in which images of the plasma jet and/or of the particle jet are recorded by means of a digital camera, characterized in that at least one region of identical intensity and/or at least one region in a defined intensity range is assigned to one or more symmetrical geometric surface bodies by means of computer processing and/or dissociation, and in that the symmetrical geometric surface body/bodies are recorded as a data set or data sets on the basis of features characteristic of the respective geometric shape, and at least one feature of the thermal spraying process which influences the quality of the sprayed layer is recorded, controlled and/or monitored using this data set or these data sets.
    2. Method according to Claim 1, characterized in that the symmetrical geometric surface bodies used are circles, squares, rectangles, parallelograms and/or preferably ellipses.
    3. Method according to either of Claims 1 and 2, characterized in that characteristic features which are independent of one another are recorded as a data set for the respective geometric shape.
    4. Method according to any of Claims 1 to 3, characterized in that the computer processing and/or dissociation is effected by means of a contour-recording algorithm, by means of a representation in gradient stages and/or by means of a gradient-based representation reduced to bit level.
    5. Method according to any of Claims 1 to 4, characterized in that the at least one feature of the thermal spraying process which influences the quality of the sprayed layer relates to the spraying process and/or the spraying apparatus.
    6. Method according to any of Claims 1 to 5, characterized in that the symmetrical geometric surface bodies or preferably the data sets thereof are used to regulate and, if appropriate, optimize one or more parameters.
    7. Method according to any of Claims 1 to 6, characterized in that the symmetrical geometric surface bodies or preferably the data sets thereof are used to document one or more features which influence the quality of the sprayed layer and/or the spraying process itself.
    8. Installation for quality assurance during production of a sprayed layer on the surface of a substrate by means of a thermal spraying method, comprising a digital camera for recording images of the plasma jet and/or the particle jet, characterized in that there are means for assigning at least one region of equal intensity and/or at least one region within a defined intensity range in the images to one or more symmetrical geometric surface bodies by means of computer processing and/or dissociation, and in that there are means for recording the symmetrical geometric surface body/bodies as a data set or data sets on the basis of features that are characteristic of the respective geometric shape, the at least one feature of the thermal spraying process which influences the quality of the sprayed layer being recorded, controlled and/or monitored using this data set or these data sets.
    9. Installation according to Claim 8, characterized in that the installation is designed in such a way that the symmetrical geometric surface bodies or preferably the data sets thereof are used to regulate and, if appropriate, optimize one or more parameters.
    10. Installation according to Claim 8 or 9, characterized in that the installation comprises means for using the symmetrical geometric surface bodies or preferably the data sets thereof to document one or more features which influence the quality of the sprayed layer and/or the spraying process itself.
    EP00105043A 1999-03-11 2000-03-09 Quality control during thermal spraying by computer processing of digital images Expired - Lifetime EP1036856B1 (en)

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    DE19910892 1999-03-11
    DE19910892A DE19910892A1 (en) 1999-03-11 1999-03-11 Quality assurance in thermal spraying by means of arithmetic revision or alienation of digital images

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    Publication number Publication date
    EP1036856A1 (en) 2000-09-20
    DE19910892A1 (en) 2000-09-14
    DE50010944D1 (en) 2005-09-22
    AU776428B2 (en) 2004-09-09
    US7043069B1 (en) 2006-05-09
    ATE302293T1 (en) 2005-09-15
    AU2068400A (en) 2000-09-14

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