Development of non-contact optical detection technology
2022-12-17 08:07:16
Although Audi Motors has always been known for its strict quality control, Audi Motors has adopted strict quality control measures during the production of its A3 sedan, but in early 2006, due to a spring in the transmission The shedding has caused Audi to have to recall 73,000 Audi A3 cars that have been sold around the world. Audi Motors is not the first car manufacturer in the world to recall its products, and so far, almost no car manufacturer has not recalled its products.
The reason why car manufacturers recalled defective cars is because of the complexity of modern vehicles. Modern cars consist of more than 14,000 parts, and defects in any part can cause serious quality problems. On the other hand, the auto parts suppliers of auto companies have also greatly increased the probability of accidents in cars. According to market observer research, the cost of European car three bags increased from 4 billion euros in 1999 to 7 billion euros in 2003. The annual turnover of the three-package in the global automotive business is as high as 17 billion euros.
Corresponding to these figures, the German industrial image processing technology sales revenue is about 1 billion euros, especially in the field of machine tool and equipment manufacturing in Germany, the sales revenue of image processing products has reached 2 digits. The image processing technology product used in the quality management system of the automobile manufacturing industry has a growth rate of 18%, which is the most important component. According to Dr. Norbert Bauer of the Fraunhofer Institute in Erlangen, the growth rate of image processing technology can reach 20%. In addition to his work with the Fraunhofer Institute and the European Allianz program, Dr. Bauer is also responsible for answering questions about image processing from automotive industry companies and obtaining certification from partners. Through the industrial application of image processing technology, Mr. Bauer has continuously confirmed the view that although optical detection technology has made great progress, its application in various fields has received certain resistance, and the phenomenon of unreliable work has appeared. Especially in the field of unfamiliar optical inspection technology.
Best application
Of course, some auto manufacturers have long experience in using optical inspection technology and are more experienced. At BMW's Dingolfing car production plant, none of the 5 and 6 series BMW cars went offline without the Dutzend image inspection system.
The HUD display system from Siemens VDO offers a high degree of flexibility. It generates visual images with driving information through multiple optical lenses and projects them onto the slanted front windshield. Due to the sharpness, contrast, and image distortion, the image displayed in the image is very unreal, so the image display quality installed in the vehicle should be verified by the projection effect.
The image inspection device is mainly composed of a plurality of fixed cameras and hardware and software connected thereto. In the production and assembly process of the car, the staff must install the complex image inspection system in the car, first fix the position and then fix it firmly, and then take it out of the car after completing the image verification task. The total detection time of image acquisition and image processing is about 30 s.
From May 9th to 12th, 2006, in the “Conuol†technology forum held in Sinsheim, testing equipment manufacturers can learn about the specific requirements of automotive manufacturing companies for image processing technology. In this technical forum, "non-contact" detection technology, especially optical inspection technology and related industrial image processing technology, is a prominent topic. According to past traditions, quality assurance technology exhibitions held in Sinsheim include exhibitors of one-dimensional and multi-dimensional coordinate inspection technology suppliers, weighing technology product suppliers and sensor manufacturers.
In this professional exhibition, the organizers highlighted the optical detection methods, and the experts showed the working principle, characteristics and applications of these optical monitoring devices. Among these special optical inspection instruments, there is a sensor system developed by Siemens to test the automotive electrical components in the production process from a three-dimensional perspective. According to the relevant personnel of Siemens, the non-contact optical detection method can eliminate the welding defects in laser spot welding 100%.
Compared with other detection technologies, this optical detection instrument has a main feature that the detection speed is fast. The detection speed of this optical detection instrument is several tens of times or even thousands of times higher than before, so that each of the original regulations can be The daily sampling test is replaced with inspection of all products, realizing the possibility of zero defect production.
In the automotive industry, optical contact inspection technology can also be used to:
â–¡ 3D online inspection of geometric position dimensions, such as dimensional inspection of three-way catalytic converters, rims, pipes and hoses;
â–¡ Surface quality inspection, such as cylinder head sealing;
â–¡ X-ray inspection, such as casting inspection;
â–¡ Thermal imaging inspection, etc.
In order to ensure the quality of the products, various testing techniques are needed in the production process to detect defects and faults and repair them in time. Test techniques can be divided into non-contact and contact tests depending on the test method. At present, non-contact testing has evolved from manual visual inspection to Automatic Optical Inspector (AOI) and Automatic X-ray Inspector (AXI).
Due to the increasing complexity of automotive parts, traditional contact testing has been greatly limited. With the continuous development of non-contact testing technology, the application of this testing method in production has also increased. And the continuous improvement of the technology itself has made it even more compelling. In the past two or three years, the application of contactless testing has seen phenomenal growth, and the growth rate is still accelerating because there are more industry leaders. The manufacturer is aware of the advantages of this technology and puts it to use.
“Quality for Success†is the slogan of the 20th “Conuol†professional exhibition. The exhibition exhibits a large number of modern inspection technologies suitable for industrial enterprise applications, including hardware and software used in 1D and multidimensional inspection technologies. Image processing technology, weighing technology and different sensors such as raw material testing, metal detection, surface inspection.
The HUD display image quality determines the size of the user base. This is the conclusion of the software system company Gefasoft and the US hardware manufacturer Cognex in 2002 after receiving the contract to develop the HUD-Quality Assurance System.
When the 2003 and 2004 years alternated, the first HUD quality inspection system was put into use. With the help of multiple cameras mounted on the vehicle, the engineers got an image of the final test results. The algorithm language of image processing can analyze and judge more than 30 feature data of each camera and each image to obtain the result of evaluation analysis.
The most important evaluation indicators are: edges, dimensions, shapes, angles, arcs, and hatching. These feature indicators are defined separately in the algorithm language, based on the system-set image and the pair of realistic detection images. Determine the spatial proportion of the object. These inspection pictures are classified and archived. When a user complaint is encountered, the inspection images stored for many years can be called up to prove the quality of the product at that time.
The reason why car manufacturers recalled defective cars is because of the complexity of modern vehicles. Modern cars consist of more than 14,000 parts, and defects in any part can cause serious quality problems. On the other hand, the auto parts suppliers of auto companies have also greatly increased the probability of accidents in cars. According to market observer research, the cost of European car three bags increased from 4 billion euros in 1999 to 7 billion euros in 2003. The annual turnover of the three-package in the global automotive business is as high as 17 billion euros.
Corresponding to these figures, the German industrial image processing technology sales revenue is about 1 billion euros, especially in the field of machine tool and equipment manufacturing in Germany, the sales revenue of image processing products has reached 2 digits. The image processing technology product used in the quality management system of the automobile manufacturing industry has a growth rate of 18%, which is the most important component. According to Dr. Norbert Bauer of the Fraunhofer Institute in Erlangen, the growth rate of image processing technology can reach 20%. In addition to his work with the Fraunhofer Institute and the European Allianz program, Dr. Bauer is also responsible for answering questions about image processing from automotive industry companies and obtaining certification from partners. Through the industrial application of image processing technology, Mr. Bauer has continuously confirmed the view that although optical detection technology has made great progress, its application in various fields has received certain resistance, and the phenomenon of unreliable work has appeared. Especially in the field of unfamiliar optical inspection technology.
Best application
Of course, some auto manufacturers have long experience in using optical inspection technology and are more experienced. At BMW's Dingolfing car production plant, none of the 5 and 6 series BMW cars went offline without the Dutzend image inspection system.
The HUD display system from Siemens VDO offers a high degree of flexibility. It generates visual images with driving information through multiple optical lenses and projects them onto the slanted front windshield. Due to the sharpness, contrast, and image distortion, the image displayed in the image is very unreal, so the image display quality installed in the vehicle should be verified by the projection effect.
The image inspection device is mainly composed of a plurality of fixed cameras and hardware and software connected thereto. In the production and assembly process of the car, the staff must install the complex image inspection system in the car, first fix the position and then fix it firmly, and then take it out of the car after completing the image verification task. The total detection time of image acquisition and image processing is about 30 s.
From May 9th to 12th, 2006, in the “Conuol†technology forum held in Sinsheim, testing equipment manufacturers can learn about the specific requirements of automotive manufacturing companies for image processing technology. In this technical forum, "non-contact" detection technology, especially optical inspection technology and related industrial image processing technology, is a prominent topic. According to past traditions, quality assurance technology exhibitions held in Sinsheim include exhibitors of one-dimensional and multi-dimensional coordinate inspection technology suppliers, weighing technology product suppliers and sensor manufacturers.
In this professional exhibition, the organizers highlighted the optical detection methods, and the experts showed the working principle, characteristics and applications of these optical monitoring devices. Among these special optical inspection instruments, there is a sensor system developed by Siemens to test the automotive electrical components in the production process from a three-dimensional perspective. According to the relevant personnel of Siemens, the non-contact optical detection method can eliminate the welding defects in laser spot welding 100%.
Compared with other detection technologies, this optical detection instrument has a main feature that the detection speed is fast. The detection speed of this optical detection instrument is several tens of times or even thousands of times higher than before, so that each of the original regulations can be The daily sampling test is replaced with inspection of all products, realizing the possibility of zero defect production.
In the automotive industry, optical contact inspection technology can also be used to:
â–¡ 3D online inspection of geometric position dimensions, such as dimensional inspection of three-way catalytic converters, rims, pipes and hoses;
â–¡ Surface quality inspection, such as cylinder head sealing;
â–¡ X-ray inspection, such as casting inspection;
â–¡ Thermal imaging inspection, etc.
In order to ensure the quality of the products, various testing techniques are needed in the production process to detect defects and faults and repair them in time. Test techniques can be divided into non-contact and contact tests depending on the test method. At present, non-contact testing has evolved from manual visual inspection to Automatic Optical Inspector (AOI) and Automatic X-ray Inspector (AXI).
Due to the increasing complexity of automotive parts, traditional contact testing has been greatly limited. With the continuous development of non-contact testing technology, the application of this testing method in production has also increased. And the continuous improvement of the technology itself has made it even more compelling. In the past two or three years, the application of contactless testing has seen phenomenal growth, and the growth rate is still accelerating because there are more industry leaders. The manufacturer is aware of the advantages of this technology and puts it to use.
“Quality for Success†is the slogan of the 20th “Conuol†professional exhibition. The exhibition exhibits a large number of modern inspection technologies suitable for industrial enterprise applications, including hardware and software used in 1D and multidimensional inspection technologies. Image processing technology, weighing technology and different sensors such as raw material testing, metal detection, surface inspection.
The HUD display image quality determines the size of the user base. This is the conclusion of the software system company Gefasoft and the US hardware manufacturer Cognex in 2002 after receiving the contract to develop the HUD-Quality Assurance System.
When the 2003 and 2004 years alternated, the first HUD quality inspection system was put into use. With the help of multiple cameras mounted on the vehicle, the engineers got an image of the final test results. The algorithm language of image processing can analyze and judge more than 30 feature data of each camera and each image to obtain the result of evaluation analysis.
The most important evaluation indicators are: edges, dimensions, shapes, angles, arcs, and hatching. These feature indicators are defined separately in the algorithm language, based on the system-set image and the pair of realistic detection images. Determine the spatial proportion of the object. These inspection pictures are classified and archived. When a user complaint is encountered, the inspection images stored for many years can be called up to prove the quality of the product at that time.
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