MXPA97003211A - Automatic installation of identification of faults for the verification of fisu - Google Patents

Abstract

The present invention relates to automatic fault identification facility for the verification of cracks during control in the process by the processing of images, according to the method of magnetic powder, in which areas with a higher concentration of fluorescent magnetizable particles are determined on the pieces by means of the fluorescence produced through the fluorescence activation lighting devices, with one or several image recording units, a collection and application facility of test medium, with which it is introduced into the circuit; an image processing unit that is indicated for the evaluation of the units of images captured with the image recording units by means of exploration and recognition of the clearer areas and for the emission of different signals based on the evaluation logic, as well as a UV lamp, at least, with measurement sensor of the intensity that is characterized because several mobile image recording units are provided, if necessary, such as cameras or video cameras, whose geometrical arrangement, focus and also operation can be verified through sensors, the voltage of the UV lamp can be regulated with Subsequent according to the signals of the computer, the testing device of the test means is disposed on a bypass line for the elimination of the test liquid, which generates a corresponding signal of the measurement of the test medium, where the signals of the test units are conducted to a computer, which compares them with the existing data and emits the corresponding signals that can produce a display through monitors, a fixed-value memory, a printer and a device for modifying the magnitudes of service, such as the voltage of the lamps, the arrangement and sensitivity of the alignment of the image registration units or even the installation stop

Description

, -. Automatic installation of fault identification for fissure verification The invention relates to an automatic fault identification system for the verification of cracks in the control in the process by processing the image, according to the method of magnetic powder, for which the areas with a higher concentration of magnetizable fluorescent particles on the pieces produced by the fluorescence activation lamps, with: one or several image recording units; an installation for collecting and applying the test medium, where the test medium is introduced into a circuit; an image processing unit that is suitable for the evaluation of units of images registered with image recording units by scanning and recognizing the lighter areas and for the emission of different signals based on the evaluation logic, as well as a UV lamp, at least, with intensity sensor , as well as a procedure for the automatic identification of cracks, for which the series of images produced with the help of lamps through image recording equipment, Samples for the test treated with the test medium for the verification of fissure failures, are processed according to a memorized program.

The recognition of automated optical faults during testing with magnetic powder in production facilities that constantly generate parts to be tested, such as for example continuous casting facilities, checks of wire ends or the like is known. At present, images of optically fluorescent dye parts are already evaluated by means of the so-called optical recognition of the image, where through the known magnetic powder method the fields that are made visible by an image recognition and optimal scanning method are recognized and compare with a fault logic memorized.

Application tests on the applicability of the process range from testing wire ends to oscillating bearings. In known facilities there is a problem that the safety and verifiability of the facilities is not achieved. There is a lack of references to the test procedure and its limits, faults in the tests and their manipulation, performance delimitation, tolerance data, etc., that they currently wish to have.

The known automatic crack detection methods have some drawbacks.

In samples for tests with edges, holes, etc. the test medium is deposited at the edges. This means that checking with the camera, compared to visual evaluation, is only possible through the formation of windows. Thus, the possible "observation" is not necessary "human" of the sample for the test and normally only the relevant part for the safety is evaluated through the window For the minimization of the non-checked surfaces due to the established check window a very exact placement of the sample is necessary for the test in front of the camera Production and positioning tolerances mean that only 80-85% of the relevant safety surface can be checked in the samples for the test.

The verification with magnetic powder not documented until now, to date has only been used for the supervision of the process due to the possibility of recognition of faults. The manufacturers of series parts dominate their manufacturing processes so well that even a fault identification probability is not too high to readjust the processes.

Through the evaluation of the display of fissure failures with cameras, the problems of assigning the geometry of the fissures to the intensity of the indications and the size of the fissures are not solved. The camera only distinguishes the differences in clarity and, therefore, all the parameters that influence clarity must be included in the reproducibility of the crack faults.

Due to the insufficient description of the natural faults and the size of the critical localizable faults that this entails, the advantage has also been made that for the evaluation of the sensitivity of the magnetic powder installations the so-called test faults are introduced. Test failures can be superficial failures made artificially in the verified product. These failures have the disadvantage that, after repeated magnetization, they can practically not be washed again and thus are no longer available for an integral test. In this case, washable failures made artificially are helpful, although these are expensive. In order to check the reproducibility of the image processing, simple cross-color cross-links or something similar are also sufficient.

By using test or part failures for tests with test failures, it is only possible to check the functionality of an installation at certain intervals, which means that a direct analysis of the failures of the parts of the installation responsible for an installation is not possible. incorrect measurement and it may also happen that the installation (therefore, before the passage of the body for the test) has already worked poorly for some time, until this defective behavior has been discovered with the body for the test. It is also not entirely certain whether the divergent measurement value is now possibly due to an incorrect positioning of the body for the test or to the subsequent formation of fissures. The method of the body for the test is therefore improvable as a procedure for regular investigation of the functionality of an installation.

During the use of the existing installations up to now, as could be verified by the measurement of the test bodies, different measurement results of the same test body were produced after a prolonged service time of the installation.

From DE-A-3907732 a device for automatic fissure checking has been disclosed, which, however, can not be self-tested. This document only monitors the operation of the camera, the intensity of the UV lamps and the means of fissure checking, although these monitoring criteria always lead exclusively to the shutdown of the installation and not to an automatic solution of failures. , that is, to self-regulation.

JP-A-57-61944 refers to a device for checking the magnetic powder suspension with automatic rear adjustment of the concentrate of the magnetic powder suspension - this device is however not combined in any way with a documentation equipment. or a fissure verification facility that can self-verify, but it is only an individual module.

This means that a safe verification in a fissure verification installation has been questioned so far based on the constant modification that is necessary to make of the parameters of the installation, such as, for example, the concentration of the suspension, the intensity of the lamps , the setting of the camera, etc.

For this reason, it is the purpose of the invention to improve the installations that work automatically by means of the method of recognizing images and cameras, so that their performance is improved and also comparatively, as well as that the errors can be identified more safely.

The function is solved by means of an automatic failure recognition system, in which there is provided an image recording unit, at least mobile, if applicable, whose geometrical disposition, focus and also operation can be verified through sensors; the voltage of at least one UV lamp can be adjusted later according to the signals of a computer; a device for testing test means is provided in a bypass line for the elimination of the test liquid, which generates a signal corresponding to the measurement of the test medium; for which the signals of the test units are led to a computer that compares them with the existing data and emits signals consequently, which can produce a display, such as monitor (s), a fixed value memory, a printer and a computer for the modification of the magnitudes served, such as the voltage of the lamp, the arrangement and sensitivity of the alignment of the image registration units or even the stoppage of the installation.

The image recording units can very advantageously be cameras, preferably video cameras. However, it can also be other recognition equipment, such as, for example, diode fields, photomultiplier devices, etc.

Preferably, the optical processing of the images is performed in the system by placing windows, scanning the window through the image evaluation unit as well as processing the data obtained in this way in a computer. .

Preferably, the intensity of the UV lamps can be adjusted later, according to the measurement signals through the output signals of the computer.

It is also possible to use UV flash lamps for the creation of images, thereby achieving, among other things, high intensities and relatively uniform exposure times.

For samples for large or similar tests, which have to be investigated on all sides, it may be necessary to rotate the sample for testing in front of the image recording units, and this rotation can be monitored through known measurements.

Preferably, the computer sends its signals to a storage medium, such as a printer for test documents, diskettes or the like, for which they also generate control signals for the installation and can also control the operation of the installation or even stop it. .

Preferably, the installation will show a magnetic field measuring probe that measures the intensity of the H field in the sample for the test traversed by the current and conducts the measured signal to the computer.

It is convenient to measure the intensity of the current that passes through the sample for the test for the formation of the magnetic field of measurement and always process it in the computer, in which it is incorporated as a measure, so that The magnetic field has been formed statutorily through the sample for the test and that the sample for the test has been placed correctly in the magnetization installation.

The invention also relates to a method for the automatic recognition of fissures, for which, with the aid of lamps, the image signals produced by means of image recording devices of the test samples treated with the test means for the verification of Fissure failures are processed according to a memorized program; for which the measurement values on the lighting of the lamps; the measurement values on the test medium in a test means test unit; the measurement values on the geometrical arrangement of the image recording devices with respect to the objects to be registered; and the measurement values on the control of the image recording device are evaluated and transmitted to a computer, which on the basis of a memorized program emits one or more signals which consequently are used for the subsequent regulation of the voltage of the lamps, dd content of the test medium, of the image recording equipment and, at least pardally, are recorded on a permanent medium, such as a test document, together with the data of the installation such as date, time of day, duration dd planting of the installation, etc.

In this way, it is possible that through the signals of the computer the installation is disconnected / stopped.

It is convenient that computer signals are recorded on a permanent medium as a test document, together with the installation data such as date, time of day, duration of operation of the installation, etc., if applicable, as well the test sample itself can be marked accordingly (seal or identification of the test).

It may also be convenient for the signals to produce the automatic change or replenishment of the test medium.

It is advantageous that perfections are obtained from the demands.

Through the fact that fundamental individual components of the test facility have to be permanently checked and this verification can be protocolized, a permanent verification and documentation of the monitoring of the check is now also possible. It is possible to paralyze the installation at any time when its operation is deficient or insuf fi cient, with which a Automatic checking of part cracks can always be considered as safe with respect to the operation of the test facility.

The invention is further explained in more detail on the basis of examples, as well as the schematic drawing of an automatic installation for checking fissures.

As can be seen in the detailed schematic representation, in the automatic fissure verification method, the pieces are pre-treated with the means for the verification of cracks in a coating installation (immersion or rolling installation, if applicable, with treatment of ultrasound). The means for checking cracks is normally a suspension of a magnetizable material, preferably ferromagnetic.

After placing the crack inspection agent, the workpiece is driven with current, forming a magnetic field in which the ferromagnetic particles are aligned. As a result of the known physical phenomena, high concentrations of particles form at the tips and edges, which lead to the accumulation of particles not only at the edges of the workpiece, but also at the edges of cracks or spikes. edges of defects in the work piece, which also act as edges. The pieces thus coated are then irradiated by a source of illumination, whereby, by means of fluorescence, the zones of high concentration of particles radiate with greater intensity than the normal metal surfaces.

Fluorescent images are recorded by an optical detection system - whether they are scanned according to a predetermined sample or registered in their entirety, and then evaluated. The result of this image registration is then directed to a computer, which compares this record with stored values and which, based on a program, emits messages about the work piece, which can be used for the evaluation of the work piece. The computer now receives, as a result of the invention, also data from the verifying installation itself, namely from a monitoring device for checking agents through the function of the checking agent, from a verification of lighting through the lighting function , eg of the UV lamp intensity; from the magnetization station through the current flow and through the magnetic field forming the workpiece; of the optical detection through its function (if necessary the focus, the distance to the object measured, the function of the camera). These signals can be treated individually or collectively in a protocol, which can be printed on a printer or another medium as a paper copy.

The operation of the installation can be occupied at any time at certain times by means of this test protocol.

The signals generated by the computer can be transmitted to a work piece, to stop the entry of the work piece or to stop the installation. It is also possible to use these signals, especially for the reconfiguration of the parameters of the installation, such as, for example, the voltage of lamps to increase their intensity; adjusting the focus of the image registration device or the geometric arrangement thereof; subsequent supply of new crack inspection agent, if the previous one has been consumed, readjusting the current through the work piece; etc.

Now that a record of the crack check facility itself has been made for the first time, it works more efficiently and more accurately than before and the possibility of reproducing the measured values is guaranteed.

A permanent control of the installation can also be carried out (if necessary, simultaneously) through data displayed on monitors monitored by an operator, who can take the necessary measures.

For this purpose, the following monitoring parameters can be determined and transmitted to the computer.

Function of the camera The invention is preferably carried out with video cameras, other optical detection systems being also possible. In systems with several camcorders it is essential to consult at regular intervals about the lens, diaphragm, focus and distance adjustment, the means known to the specialist available (eg digital) and any changes in the automatic adjustment of the target to be detected, documenting and / or alarm to shoot. The practice has shown that authorized and unauthorized persons modify the camera setting, putting the installation in an uncontrollable state.

When changing the geometry of the workpiece, it may be appropriate to have objective adjustment values stored for each part geometry in the system and to automatically assign the cameras during the automatic change of workpieces to the computer in order to avoid the expensive adjustment works.

Lamp function Because the excitation radiation is extremely important for the generation of fluorescence, because it mainly determines the fluorescence intensity, which also governs the integrated sensitivity of the installation - its function should be monitored permanently. As is known, the spectrum of lamps varies by aging, especially in the high-energy part. This decrease in light intensity automatically leads to a defective detection of defects, since less fluorescence excitation is emitted. Based on the invention, it is proposed to monitor the intensity of the lamp through a sensor, which preferably measures the spectrum only in the area of fluorescence excitation of the spectrum. The modifications of the lamp intensity can then be compensated for by simply increasing the lamp voltage. Otherwise, the lamp must be replaced or the sensitivity of the image registration unit must be readjusted appropriately.

Monitoring of the test fluid The automatic display evaluation with the Opto-Tec system reacts only to differences in brightness. In the consumption of checking agents during the check, it may either decrease the defect display brightness proportionally together with the background display brightness, or also only the defect display brightness. But both luminosities give rise to the possibility that the reproduction of the installation is lost with the consumption of testing agents.

The installation contains an automatic work ASTM bulb, which is an integral part of a parallel message with the same date. The checking agent monitoring unit is dimensioned to monitor the testing agents and can be used with close tolerances for the monitoring of the test liquid and for the improvement of the reproducibility. In particular, the evacuation of molten test parts is relatively large, as, for example, in the automotive industry, checking agents are re-evaluated and the possibility of reproducing the measurements is substantially disturbed without monitoring.

The monitoring installation of automatic work checking agents provides help here, allowing a permanent control of the checking agent and, if necessary, also allowing its automatic complement.

The signals from the computer can also be transmitted by means of a data transmission, so that the transmitted data allow remote diagnosis. Otherwise, important functions of the installation, magnetization circuit, stop device cycles, etc. can be displayed on a monitor.

The required performance of the computer can, for example, be obtained by means of an industrial PC and a graphic card, both to allow fast operation.

The times per piece elevated on the one hand and the different surfaces relevant for safety on the other hand, can lead to costly parallel connections of cameras as image recording devices. For example, in the manufacture of automobiles, symmetrical left and right 9 chambers are required for each side, which can be moved in series from station to station, but always checking a single segment. By checking almost in parallel you get a high number of cycles. A disadvantage of this system is also based on the fact that the illumination of the surface to be investigated must be using a UV lamp. This means that all the insecurities linked to UV lamps can be presented 18 times.

There is the possibility of several alternatives: - Positioning of a piece and evaluation of the presence of cracks with several chambers, which are directed to the piece. Disadvantage is here the high number of cameras and one call of each camera displaced in time. This prolongs the time per piece, being possible the reciprocal damages.

- Check product stopped and moveable camera. The mechanical transport of the camera is essentially more bulky than the cameras connected in parallel.

In a camera system, the work piece is held by an automaton correctly positioned in register position in front of the camera. If, for example, complicated castings are transported after the magnetization to an observation post, the parts are clamped once at two support points and rotated in front of the observer. The observer can stop the rotation process to make a more in-depth observation of the visualizations.

After setting the relevant surface areas for safety, the part is rotated, preferably automatically. Parallel to the rotary transmitter is an angular support, which controls both the rotary movement and also activates the respectively positioned and adjusted cameras. UV radiation can through UV flashes, performed almost once for all cameras. By means of this system the number of cameras can be drastically reduced, obtaining an optimization between the number of cameras and the possibly necessary mechanical movement of the cameras.

Although the invention was explained on the basis of selected exemplary embodiments, alterations of the same are possible for the specialist, which are also included in the scope of the rights, so that the invention is in no way limited to the Execution examples.

Claims (6)

1. j 6 Patent vindications Automatic identification of fault identification for the verification of cracks during the process control by means of the image processing, according to the magnetic powder method, in which the areas with a higher concentration of fluorescent magnetizable particles on the pieces are determined by means of the Fluorescenda produced through fluorescent activation lighting devices, with one or more image recording units; an installation for collecting and applying a test medium, with which it is introduced into the circuit; an image processing unit that is indicated for the evaluation of the units of images captured with the image recording units by means of scanning and recognition of the lighter areas and for the emission of different signals based on the evaluation logic, as well as as a UV lamp, at least, with an intensity measuring device characterized in that several mobile image recording units are provided, if necessary, such as cameras or video cameras, whose geometrical arrangement, focus and also operation can be checked through sensors, the voltage of the UV lamp can be adjusted later according to the signals of the computer, the testing device of the test medium is arranged in a bypass line for the elimination of the test liquid, which generates a corresponding signal of the measuring medium of the test medium, where the signals of the test units s are conducted to a computer, which compares them with the existing data and outputs the corresponding signals that can produce a display through monitors, a fixed-value memory, a printer and a device for modifying the service quantities, such as the tension of the lamps, the arrangement and sensitivity of the alignment of the image registration units or even the stoppage of the installation.
2. 2. Installation according to claim 1, characterized in that the optical processing of the images is carried out by establishing windows and scanning the window through the image registration unit, as well as the processing of the data obtained therefrom. a computer.
3. 3. Instalation according to one of the previous claims, characterized in that the images are registered with UV flashing lamps.
4. 4. Installed according to one of the preceding indications, characterized in that the sample for the test can be rotated in front of the image recording units.
5. 5. Installed according to one of the previous rdvindicadones, which is characterized by having provided a magnetic field measuring probe, which measures the intensity of the field H in the sample for the test, traversed by the current and leads the measurement signal to the computer and because a measuring device is provided for the intensity of current that passes through the sample for the test intended for the formation of the magnetic field, which measures it and conducts the measurement signal to the computer, where it is processed.
6. 6. Procedure for the automatic recognition of fissures where, with the help of lamps, the series of images generated by the image recording devices of the samples are processed for tests treated with the test means for the checking of fissure failures, according to a memorized program; which is characterized by the values of the measurement on the lighting of the lamps; the measurement values on the test medium in a testing unit of the test medium; the measurement values on the geometric arrangement of the image recording devices with respect to the objects to be registered; and the measurement values on the setting of the image recording device are recorded and transmitted to a computer that emits one or more signals based on a memorized program which are used in accordance with the subsequent regulation of the voltage of the lamps, the content of the test medium, the image recording device and, at least pardally, are recorded in a permanent medium, such as a test document, together with the data of the installation such as date, time of day, duration of the service of the installation, etc. (Legende von links nach rechts, oben nach unten!) 1) Checking agent 2) Test document 3) Checking agent monitoring 4) Optical detection 5) Image signals 6) Computer 7) Control of the installation 8) Workpieces 9) Installation for layer coating 10) Workpiece treated 11) Magnetization station 12) Workpiece checked 13) Humiliation 14) Signal through the exposure function