CN116234691A - Imaging system and method for determining defects in glazing - Google Patents
Imaging system and method for determining defects in glazing Download PDFInfo
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- CN116234691A CN116234691A CN202180063888.1A CN202180063888A CN116234691A CN 116234691 A CN116234691 A CN 116234691A CN 202180063888 A CN202180063888 A CN 202180063888A CN 116234691 A CN116234691 A CN 116234691A
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Abstract
The present disclosure provides an apparatus and method for determining defects and using multi-response imaging and sensor fusion to determine defects related to a welding process in an automotive glazing production line. The disclosed device (100) is used for determining defects in vehicle glazings. The apparatus comprises a plurality of sensors (101) configured to obtain at least a temperature, an image of one or more connection areas on a vehicle glazing during a welding process on the vehicle glazing. The apparatus further comprises a data acquisition system (102) and a control unit (103), the data acquisition system (102) and the plurality of sensors being operably configured for obtaining data from the sensors, the control unit (103) comprising a processing unit operably configured for analyzing the occurrence of defects during the welding process based on the analysis module. The apparatus further comprises an alarm unit (104), the alarm unit (104) being adapted to provide an alarm when the occurrence of a defect is detected.
Description
Technical Field
The present disclosure relates generally to systems for determining defects, and more particularly to systems for determining defects associated with a welding process using multi-response imaging in a glazing (glazing) production line. The present disclosure also provides a method for monitoring solder quality of a glazing.
Background
The background description includes information that may be useful for understanding the present disclosure. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed disclosure, or that any publication specifically or implicitly referenced is prior art.
The automotive glazing or vehicle glazing may include windshields, side windows, four-sided windows, backlights, and the like. It may be a laminated glazing or a tempered glazing. Automotive glazing lines have many sub-processes that can be improved by using imaging systems. In an automotive glazing production line, there may be a specific station at which the glazing with the connector may be welded by a welding process known in the art. The welding may be performed on a laminated glazing or a tempered glazing. In such processes, defects may occur in the process, resulting in defects in the glazing itself. Defects occurring due to manual or automatic processes need to be captured and corresponding measures taken.
Referring to US2019084070A1, US2019084070A1 relates to a MIG welding system comprising: the vision module and the welding apparatus are operated, a thermal image of the welded component is captured using an Infrared (IR) thermal camera connected to the vision module, the image is converted into a video signal and the video image is transmitted to the vision module, whether there is slag is detected by the vision module, whether the detected slag is fixed is determined when slag is detected by the vision module, and when the detected slag is determined to be fixed, the position of slag is analyzed and coordinate values are calculated.
Also, referring to CN108562614a, CN108562614a discloses a chip pin bonding defect detection system and method based on thermal imaging detection. The system comprises a thermal imager, a tested chip and a processing module, wherein the thermal imager is used for detecting the temperature difference between the pin welding point of the tested chip and the background, and recording the temperature field distribution of the surface of the welding point so as to obtain an infrared thermal image video of the pin welding point of the tested chip. The processing module is used for processing the infrared thermal image video to obtain a welding defect result of the pins of the tested chip.
Furthermore, patent documents EP2714602 (A1) and FR2975687A1 are referred to, which describe a system for reading information about defects present in sheet glass. This involves comparing the defective area with an area having a predetermined area that is free of defects to determine if there are any defects on the glass and the cutting system is used to remove the defective section from the sheet glass by creating an optimal cutting plane for the glass.
Further references WO2015121548 (A1), WO2015121549 (A1) and WO2015121550 (A1) describe a system for reading bar codes etched into a glass panel so that the bar code can be read through the major face of the panel and also through the thickness of the panel. To achieve this, a backlight is required to illuminate the bar code so that the bar code can be captured by the imaging system and read by the system.
In the above prior art there are some drawbacks and limitations, for example the proposed solution is an off-line process for welding monitoring, the process control involved in the solution involves manual intervention, and the welding defect identification is performed after the welding process. Thus, there is a need to improve the predictive model and monitoring method by means of image AOI (region of interest). It would therefore be desirable and advantageous to provide an imaging system for reducing defects during a welding process and a method for monitoring a welding process in real time.
Disclosure of Invention
These and other objects of the present invention are achieved by the following aspects of the present invention. The following disclosure provides a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This presents some concepts of the invention in a simplified form as a more detailed description of the invention as presented later. It is a comprehensive overview of the disclosure, rather than a broad overview of the invention. This summary is intended to provide a basic understanding of some aspects of the invention.
It is an object of the present invention to overcome the drawbacks of the prior art solutions.
It is another object of the present invention to provide a solution for monitoring in real time the welding process on a glazing in an automotive production line.
It is another object of the present invention to perform multi-criteria optimization of a welding process on a glazing in an automotive production line.
It is another object of the present invention to provide a method of monitoring the temperature at a welded joint on a glazing in an automotive production line through glass.
It is another object of the present invention to provide a method for monitoring a welding process in real time for identifying defects using stress-based corresponding temperatures as indicators in the welding process.
It is another object of the present invention to provide a solution for identifying lots and matching system parameters to improve and thereby control welding parameters, thereby providing alarms and enhancing traceability of glass.
In one aspect of the invention, an apparatus for determining defects in a glazing is disclosed. The apparatus includes a plurality of sensors configured to obtain at least a temperature, image of one or more connection areas on the glazing during a welding process on the glazing. The apparatus further comprises: a data acquisition system operably configured with the plurality of sensors for obtaining data from the sensors; a control unit comprising a processing unit operably configured with the data acquisition system for analyzing the occurrence of defects during the welding process based on the analysis module; and an alarm unit operatively configured with the control unit for providing an alarm when the occurrence of a defect is detected. The control unit is configured to: defect identification is performed by inspecting the surface of the welded area on the glazing or its connection prior to or during the welding process. The analysis of defect identification is based on: solder material in contact with the surface of the substrate of the glazing and solder material in contact with the connector undergoing the soldering process, and sensor fusion data acquired from a plurality of sensors for optimal detection of defects in the glazing.
In another aspect of the invention, a method of detecting defects in a glazing during a welding process is disclosed. The method comprises the following steps: obtaining, by an imaging unit, images of a surface of a substrate for a glazing from one or more sensing devices, the sensing devices including a High Definition (HD) camera and a thermal camera; and preparing, by the control unit, the obtained image for analyzing the occurrence of defects by generating temperature and time array data. The control unit will also obtain thresholds for analyzing the maximum value, the minimum value, the ambient temperature and identify peak temperature values based on inputs from boundary conditions, and the control unit will compare the temperature obtained from the sensing unit with the calculated thresholds. The method further comprises the steps of: if the temperature obtained from the sensing unit is greater than the threshold value, the data acquisition system begins recording data and further analyzing the occurrence of defects. The control unit will also compare the surface temperature of the substrate of the glazing with a reference and if the obtained temperature is greater than the error margin, the control unit triggers a signal for adjusting or stopping the welding process on the glazing.
Aspects of the present invention relate to solutions related to online defect detection during a process of welding contacts on an automotive glazing (e.g., contact welding of a backlight panel) and correlate data obtained from theoretical stress calculations to determine if there is any stress resulting from locally heating the glazing surface, such as the backlight panel in the example, that causes the backlight to crack. The drawbacks mentioned in the background are overcome by an optimized imaging system that facilitates the detection of glass models to determine welding parameters.
Imaging systems and methods of monitoring the temperature at a welded joint (across thickness) through glass are simple and effective solutions that require placement to align the camera system in a less invasive arrangement. The solution enables real-time monitoring of the welding process. It involves real-time comparison of temperature and thermal stress between actual and calculated data, thereby performing multi-criteria optimization. The solution also enables the use of predictive methods to reduce defects during the welding process and to create optimized welding process parameters. In addition, it can identify lots and match system parameters in order to improve and control welding parameters to provide alarms, which will enhance traceability of the glass.
The salient features of the invention, as well as the advantages thereof, will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses a computer.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and to assist those skilled in the art, illustrate embodiments of the invention. It is evident that the figures in the following description illustrate only some embodiments of the invention and that those skilled in the art may derive other figures from the figures without departing from the scope of the disclosure.
Fig. 1 (a) to 1 (c) show block diagrams of solutions for determining defects in vehicle glazings according to embodiments of the present invention.
Fig. 2 (a) to 2 (b) show exemplary embodiments of a solution according to the invention for determining defects in a vehicle glazing.
Fig. 3 (a) shows two sides of a glass sheet as known in the art.
Fig. 3 (b) shows different layers of solder material, connectors and glass according to an example of the invention.
Fig. 3 (c) shows the elongation of glass and solder materials according to examples of the invention.
Fig. 4 (a) shows a block diagram of traceability of a vehicle glazing according to an embodiment of the invention.
Fig. 4 (b) shows a method of detecting defects in a glazing during a welding process according to an embodiment of the invention.
Fig. 5 (a) to 5 (e) show experimental details of a scene of defect detection according to an embodiment of the present invention.
Fig. 6 (a) to 6 (c) show experimental details of a scene of defect-free detection according to an embodiment of the present invention.
Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve the understanding of the embodiments of the present disclosure.
Detailed Description
The present disclosure will now be discussed in more detail with reference to the accompanying drawings attached hereto. Those skilled in the art will appreciate that this description is helpful in understanding the present invention, but these are merely exemplary.
The terms and words used in the following description are not limited to literature meanings, and the same terms and words are used to achieve clear and consistent understanding of the present invention. Thus, the terms/phrases should be read in the context of this disclosure, rather than read in isolation. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.
Features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way in one or more other embodiments and/or in combination with or instead of the features of the other embodiments.
The present disclosure describes a monitoring or imaging system that facilitates detection of anomalies in a welding-related parameter in a vehicle glazing during a welding process in a vehicle glazing production line. The present disclosure also provides a method of monitoring the temperature at a welded joint (across thickness) through glass. In this disclosure, a particular station for (welding) a vehicle glazing with a connector is contemplated. Faults occurring during welding and defects thereof in the vehicle glazing due to manual or automated processes are easily captured and updated into the disclosed system to alert an operator or take corrective action. The present disclosure uses sensor fusion, such as, but not limited to, infrared (IR) cameras, temperature sensors, to monitor and control the welding of contacts on a vehicle glazing. The welding processes indicated herein include welding in connection with any type of surface (e.g., without limitation, glass, black ceramic painted areas, i.e., BCP or single or double vehicle glazings), and also include integrated methods involving heating and bonding, such as welding (resistance, hot air, gun, etc.), brazing, friction stir welding.
In an embodiment of the invention, an apparatus (100) for determining defects in a vehicle glazing as depicted in fig. 1 (a) is disclosed. The disclosed apparatus includes a plurality of sensors (101) configured to obtain at least temperature and stress on a vehicle glazing during a welding process, and a data acquisition system (102) operably configured with the plurality of sensors for obtaining data from the plurality of sensors. The apparatus further comprises a control unit (103), the control unit (103) and the data acquisition system being operably configured for analyzing the occurrence of defects based on the analysis module or the calculation module. The apparatus also has an alarm unit (104), the alarm unit (104) and the control unit being operably configured for providing an alarm when the occurrence of a defect is detected. The control unit may comprise a processing unit. It may be possible to create a plurality of data tracks including temperature difference tolerance, temperature distribution of the weld area, weld duration. The plurality of sensors (101) are configured to obtain parameters for inspecting a surface of the vehicle glazing, the parameters being at least a temperature and an image of one or more connection areas during a welding process for the vehicle glazing and a stress on the vehicle glazing. Other parameters may include, but are not limited to, the power drawn by the bonding tool during the process.
In an embodiment of the invention, an apparatus for determining a defect in a vehicle glazing according to an embodiment of the invention is disclosed, the apparatus having an actuator as an alarm unit. The plurality of sensors (101) in the device comprises at least an imaging unit. The imaging unit includes a High Definition (HD) camera and a thermal camera configured for image acquisition and analysis of a welding process, and is positioned such that a field of view of the unit is consistent with the welding process performed on a vehicle glazing. The thermal camera is configured with HD camera imaging output as an input parameter for correlation with the thermal camera to identify defects during welding. The thermal camera is optimally positioned to obtain the maximum and average temperatures of the welding process. Defect detection may be implemented by means of image fusion segments for identifying the cause and location of defects.
Referring again to fig. 1 (b), an exemplary embodiment of a system for adjusting a welding process in a vehicle glazing according to an embodiment of the invention may be depicted. The system comprises: a sensing unit (201), the sensing unit (201) comprising a plurality of sensors configured to obtain at least a temperature and a stress on a vehicle glazing during a welding process; and a data acquisition subsystem (202), the data acquisition subsystem (202) and the sensing unit being operably configured for obtaining data from the sensing unit (201). The system further comprises a control unit (203). The control unit (203) comprises a processing unit operably configured with the data acquisition system for analyzing the occurrence of defects based on the analysis module. The system further comprises an actuation unit (204), the actuation unit (204) and the control unit being operably configured for adjusting the soldering process based on the solder-induced stress on the surface of the substrate of the vehicle glazing obtained by the analysis module. The system includes the same calculation model and analysis module as those related to the equation further established as equation (1) below. An analysis module or calculation module for analyzing the occurrence of defects in a vehicle glazing during a welding process may include calculations made taking into account instantaneous and historical data of stress and temperature of the surface of a substrate of the vehicle glazing. The sensing unit (201) may be mounted on a robotic arm or gantry system to facilitate access to a wider conveyor or to obtain different angles by a reduced number of sensors. The sensing unit (201) comprises at least: an imaging unit (311), the imaging unit (311) comprising a High Definition (HD) camera and a thermal camera configured for image acquisition and analysis of a welding process. The actuation unit (204) is further configured to stop the welding process in case of an abnormality in the welding process. The system may also include a power sensor configured to monitor a supply of power on one or more elements performing the welding process. The disclosed system includes sensor integration. Sensor integration determines the process parameters and Quality Control (QC) of the heater grid.
In an implementation of the invention, the imaging unit (311) is operably configured with a control unit (312), which control unit (312) is in turn operably configured with an actuator (313), as shown in fig. 1 (c). The control unit (312) comprises a processing unit (3122), the processing unit (3122) being configured to coordinate with the data acquisition system (3121) and the actuator controller (3123). The actuator controller (3123) is capable of controlling the actuator (313). In an embodiment, the actuator is used to transfer a defective panel to an auxiliary line for further inspection. The actuator (313) referred to in the figures may be, but is not limited to, a manual actuator or an automatic actuator. The type and nature of the actuator will depend on the nature of the control over the system. When the welding process is manual, if the temperature exceeds a certain range, which may result in stress build-up, there may be an indicator that may instruct the operator to stop the welding. In the case of an automated process, where the welding system is mounted to an automated system (which may be similar to simply moving the welding system onto or off of a glass or robotic system), better control of the process may be achieved based on temperature and predicted stress values from the generated model. In the event that the process is not controlled (for both manual and automated systems) and the welding temperature exceeds the limit, the glass is moved by the conveyor to a different area for observation (e.g., checking for crack formation/breakage). The actuator of the system may be a conveyor system for processing glass. Those skilled in the art will appreciate that the actuator may include one or more of such examples and combinations thereof mentioned herein, although not limited to these. The imaging system according to the invention may be mounted on a robotic arm or gantry system in order to access a wider conveyor or to obtain different angles using reduced sensors. The control unit (312) is configured to obtain data from the sensors and to obtain historical or reference data from the storage device for use in adjusting the welding process. The system may comprise a visualization unit (315), the visualization unit (315) being adapted to display an alarm or data obtained from the sensor.
In an implementation of the invention, the sensor is configured to communicate with the data acquisition system using one or more communication methods, and the data acquisition system may have a dual connection with a storage device or server, as already shown in fig. 2 (a). These connections may be wired or wireless. The sensors may include, but are not limited to, infrared (IR) cameras, imaging devices, high Definition (HD) imaging devices, ultrasonic sensors, and current sensors. The data acquisition system may include: an analog-to-digital converter (ADC), camera interface or communication protocol (CSI/SPI) connected to the current sensor is used to connect peripheral devices such as sensors and imaging devices to a Central Processing Unit (CPU) that is connected to the transceiver module. The transceiver module may be wired or wireless, such as but not limited to Wi-Fi, bluetooth, etc.
The disclosed apparatus according to the described implementation of the present invention further comprises a storage server or an Application Programming Interface (API) block. The storage server block may store data, perform analysis, and transfer data from the sensor to a server or visualization medium. The imaging unit also includes image acquisition by using HD and IR cameras and analysis of the welding process. The apparatus may include a power sensor configured to monitor a supply of power on one or more elements performing a welding process. This arrangement enables alignment of the camera system in a less invasive manner without impeding the welding process. The alarm unit (104) may comprise a visualization device configured to sound an alarm upon detection of occurrence of any defect. For manual systems, this function can alert the operator. As shown in fig. 2 (a), the visualization device may be a handheld device for monitoring various data points of the system. The visualization device may include, but is not limited to, a human-machine interface (HMI) on a control panel, portable device, mobile phone, tablet, notebook, etc.
In an implementation, a process flow is disclosed that analyzes data from a thermal camera, as shown in fig. 2 (b). The imaging system disclosed herein takes input from a thermal imager to generate data such as temperature versus time array and thereby generate waveforms to view real-time data. From the acquired temperature data, a threshold value, a maximum value, a minimum value, a room temperature, etc. may be generated along the rising and falling edge detection of the value of the parameter under consideration. The temperature may be compared to a threshold and if the temperature is found to be above the threshold, data logging is initiated for analysis to create a temporary array for storing data points greater than the threshold. In addition, reference is made to welding temperature data based on theoretical calculations (taking into account glass mechanics). The real-time temperature obtained is compared to reference welding temperature data and if it is greater than normal, appropriate action is taken, such as triggering a warning to alert the welding process or triggering an actuator to stop or adjust the welding process. The system is capable of monitoring the welding process while taking into account the possibility of errors in the system.
In an implementation of the invention, the thermal camera may be placed such that the field of view of the camera coincides with the weld area on the vehicle glazing panel. When the welding process begins, the thermal imager is configured to capture data and compare the collected data to a pre-fed reference. If the real-time value thus obtained is within the set limits of the reference, the process is considered good. However, if the obtained value deviates from the set limit reference, the vehicle glazing is isolated. The imaging features of the device include the sensor, a data acquisition system capable of detecting defects or anomalies in welding parameters during the welding process, a storage device/server, and a visualization tool. The imaging unit can assist the apparatus in determining parameters such as stress through the glass to monitor the welding process based on established boundary conditions, which may include, but are not limited to, reference data for a particular type of glass, minimum temperature, maximum temperature, etc.
HD and IR images may be superimposed to obtain the desired sensor results. The thermal camera is configured to use the HD imaging output as another input parameter to correlate with the thermal camera for identifying defects during welding, and it is positioned such that the field of view of the camera is consistent with welding on the vehicle glazing panel. When the welding process begins, the thermal imager captures data and compares the collected data to a reference. The data captured from the one or more sensors may include temperatures obtained over an area, within a surface, and through a vehicle glazing. For example, if welding is performed on face 1 of the glass, the sensor is configured to obtain the temperature in face 2. Referring to fig. 3 (a), an exemplary embodiment of different sides of a glazing in a vehicle glazing is shown to supplement the understanding of the stress achieved through the glazing. Sensor fusion techniques may be used to replace one or more sensing devices. It may include other parameters such as, but not limited to, optical data, images from HD and IR cameras, and power drawn. The device may use a temperature probe or a power measurement sensor. Images of the temperature distribution in and around the weld area are obtained from the IR camera and superimposed with the HD image to identify defects during the welding process. If the fruit value is within the set limits of the reference, the process is considered good. If the real-time value shows a deviation, the glass is isolated. Referring to fig. 3 (b), fig. 3 (b) discloses a layered view of the arrangement of connectors, solder material and glass underneath. In an embodiment of the invention, the control unit (103) is configured for defect identification by inspecting the surface of the welding area or a connection thereof prior to the welding process. Defect identification is based on solder material in contact with the surface of the substrate of the vehicle glazing and solder material in contact with the connector undergoing the soldering process.
With reference to an implementation of the invention, wherein the imaging unit may be mounted at an optimal distance from the vehicle glazing panel, focusing on the area under the weld. The device is thereby able to obtain a maximum, average temperature on the face 2 of the vehicle glazing during the welding process on the face 1. The parameter curve (profile) thus obtained is used for comparison with a standard curve to find any deviation. The standard curve will be predetermined and will be fed into the control unit. Glass that deviates from the standard value is then isolated to evaluate the stress.
In an implementation of the disclosed embodiments, the stress-related temperature is a set boundary for weld monitoring. The temperature on the materials involved during the welding process is calculated computationally. The stress on the glass can be calculated as a function of the time period after the soldering process. The critical stress point may be noted and the temperature corresponding to the stress is given as a boundary condition. Based at least on the boundary conditions and the material properties involved, a stress distribution on the glass can be obtained. The boundary conditions may be set for analysis purposes and may be defined for particular modules (e.g., individual models of glass and individual regions for welding, etc.). From the data observed from the temperature and the stress developed, the mean and standard deviation of the glass satisfying the parameters are calculated and qualified for further steps. Since stress builds up over time and may even cause the glass to break in one week or 10 days, glass exceeding the temperature parameters of the process is isolated for observation. The temperature range of a particular process and boundary conditions associated with the analog values are determined.
In an embodiment of the invention, the surface inspection of the vehicle glazing during the welding process is given by the stress on the surface of the substrate of the vehicle glazing, which is given by:
where F is the force acting on the area a of the vehicle glazing, Δt is the difference between the maximum temperature involved during the soldering process and room temperature, α1 is the coefficient of thermal expansion of the solder material, α2 is the coefficient of thermal expansion of the surface in contact with the solder material, E1 is the young's modulus of the solder material, and E2 is the young's modulus of the surface in contact with the solder material.
The calculations made herein can be split in half, i.e. calculations involving solder material in contact with the glass and calculations involving solder material in contact with the connector. The expansion or contraction of a material upon exposure to heat can be explained by the theory of expansion or contraction. When two blocks in contact with each other are exposed to heat, they expand or contract relative to each other, finding a balanced expansion or contraction. These calculations were obtained using the thermal expansion concept. Typically, during soldering, a connector with solder material is placed on the glass surface of a vehicle glazing and heat is provided to the connector. Typically, the temperature in the solder material increases above 300 ℃. As a result, the solid solder material melts and cools further, becoming solid again, thereby connecting the connector to the glass. When the solder material again begins to form a solid and reaches 50 ℃ and 25 ℃, stress begins to develop on the glass. It has been observed that stresses are generated at the beginning of the solidus point of the solder material, both materials elongating at different amplitudes depending on the coefficient of expansion of the individual materials. Solders with a larger expansion coefficient than glass tend to expand more than glass materials. Referring to fig. 3 (c), differential heating of the material is shown. Δl1 shown therein depicts the elongation of the solder material, Δl2 represents the elongation of the glass, Δle represents the equilibrium elongation of the two materials, Δ1 represents the decrease in length due to the compressive force of the glass acting on the solder, Δ2 represents the increase in length due to the expansion force of the solder material acting on the glass, αg is the thermal coefficient of the glass, and αs is the thermal coefficient of the solder material. In the equilibrium state, the compressive force acting on the solder material due to the resistance of the glass to expansion and the tensile force acting on the connecting surface of the glass due to the expansion of the solder are both equal. The calculation module for analyzing the occurrence of defects in a vehicle glazing during a welding process includes calculations made taking into account instantaneous and historical data of stress and temperature of the surface of a substrate of the vehicle glazing.
In an embodiment of the invention, traceability of glass is disclosed if there is a deviation from normal during the welding process on a vehicle glazing. Fig. 4 (a) shows a block diagram of traceability thereof. The system disclosed in accordance with the present invention can support identifying and recording glass numbers, batches, and models in a production line in a database. This data can be used to create historical information for further predictions and precautions of the process. The data acquisition system (102) may be configured to obtain and further record one or more parameters associated with the vehicle glazing to enable traceability of the vehicle glazing in the event of deviations from normal conditions during the welding process.
Sensor inputs and other inputs for traceability of glass may include glass thickness, glass model, glass geometry identification, welding power, and thermo-mechanical stress model. The analysis engine of the control unit is able to acquire glass characteristics, including machine and stress responses, and coordinate with a storage device or server to achieve the desired traceability of the glass. In this embodiment of the invention, the traceability of the glass may be limited to only rejected vehicle glazings and may be identified as a control feature of the system disclosed herein. In this embodiment, the glass may be transferred to an auxiliary line for further inspection by known glass panel transfer mechanisms. Furthermore, all such glass panels may be numbered sequentially prior to the welding process so that defect cases may be marked in a database for process control.
In an embodiment of the invention, a method of detecting defects in a vehicle glazing during a welding process is disclosed, as depicted in fig. 4 (b). The method may begin with: an image of a surface of a substrate of a vehicle glazing is obtained (S101) from one or more sensing devices, including a High Definition (HD) camera and a thermal camera, by an imaging unit. Further, the method includes preparing (S102) the obtained image for analyzing occurrence of defects by generating temperature versus time array data. The preparation is performed by the control unit. Then, a threshold value for analyzing the maximum value, the minimum value, the ambient temperature is obtained (S103) by the control unit for identifying the peak temperature value based on the input from the boundary condition. Then, the control unit compares the temperature obtained from the sensing unit with the calculated threshold value (S104). Then, if the temperature obtained from the sensing unit is greater than a threshold, the data acquisition system records (S105) the recorded data and an analysis of the occurrence of the defect. The control unit compares the surface temperature of the substrate of the vehicle glazing with a reference (S106). If the obtained temperature is greater than the error margin, the control unit now triggers (S107) a signal for adjusting or stopping the welding process on the vehicle glazing.
The device according to the invention has been tested to check deviations from normal conditions during the welding process in a vehicle glazing. The camera is mounted 400mm to 500mm from the vehicle glazing panel and is focused in the area below the weld. Thus, the highest temperature, average temperature, on the face 2 during the welding process is obtained. This curve is additionally used to compare to a standard curve to find any deviation, and such vehicle glazing will be isolated to evaluate stress. The sampled sensor data according to the present invention provides a sampling rate and a sleep mode. The comparator compares the actual data with the reference data. According to the invention, the stress-related temperature is a set boundary for welding monitoring. The temperature on the material involved during the welding process has been calculated computationally in a calculation data block.
A procedure can be seen if the average temperature shown by the IR camera can be correlated with the computationally calculated temperature distribution values. During the welding process, the temperature on the outer surface has been captured. There are now two possible cases to determine: the power supplied is just sufficient for the melting temperature and is much higher than necessary (causing a runaway situation of the solder material). The temperatures corresponding to the two scenarios must be checked and the material behaviour of the solder material must be checked to determine the type of defect that may occur at higher power foot of bridge.
Once the factors are determined, a model is designed in the finite element analysis software to check the stress. If the stress formed is within the allowable range, the temperature corresponding to the model is set as a boundary condition, which can be said to be within acceptable limits. If the stress is not at the boundary condition, the temperature corresponding to the stress is deemed unacceptable, thereby indicating the likelihood of a defect. Measurement of stress on a vehicle glazing during a welding process may utilize a polarizer (polarized scope) to obtain pre-and post-weld mechanical stress data.
Here, for stress calculations, the materials involved include glass, solder materials (e.g., alloys of tin, silver, and copper), and connectors (e.g., stainless steel). Some assumptions and methods made include: assuming that the blocks are composite blocks in contact with each other, the black and silver layers are eliminated, they are part of the automotive glass, no time dependence is considered, and no thickness of the glass is considered, because the focus is now on the contact of the two materials, assuming that the stresses are caused by the cooling and solidification of the solder material, and the temperatures of the various components in the model are independent of each other (because they have their own cooling rates).
The temperature on each material involved in the welding process has been given as input for calculating the stress, which is calculated computationally by finite element analysis. Furthermore, the stress on the glass has been calculated computationally as a function of the time period following the soldering process. The critical stress point has been noted and the temperature corresponding to the stress is given as boundary condition, i.e. the tensile stress is 140Mpa and the temperature condition is 150 ℃. In view of the disclosed calculation model, stresses defined in terms of coefficient of thermal expansion and young's modulus are provided in equation (1). The following table provides calculated different tensile stresses due to welding on a vehicle glazing:
TABLE 1
Embodiments of the present invention may also include identifying lots and matching system parameters to improve the effectiveness of the system and then controlling welding parameters to provide an alert. The analytical data model according to the invention improves the model with accurate set points for welding. This includes pressure points, boundary conditions, and welding parameters. Multiple weld simulations with different sets of electrode locations on the connector connecting the heating network to the battery can be obtained to see temperature profile changes and resulting stresses. In addition, temperature differential tolerances, multiple sets of traces may be defined during welding and computation.
INDUSTRIAL APPLICABILITY
In an embodiment, the disclosed imaging system for determining defects in automotive welding includes a multi-response imaging system that can be used for heating grids, antenna wire (automotive) welding, gypsum dam curing, CFL wire curing, glass guide wires.
Experimental details available from factory production line：
Referring to fig. 5 (a), data obtained during the process of welding glass from a manufacturing plant is shown. Thermal images of the temperature on face 1 of the glazing in a vehicle glazing are obtained for lower and higher powers by means of the apparatus according to the invention, and the apparatus is further configured to capture an average temperature and to verify it using finite element analysis simulations in order to correlate the stress on face 2 with the temperature on face 1. As described in detail hereinabove, the apparatus according to the embodiment of the present invention is capable of calculating stress through glass, after which parameters such as temperature are obtained, wherein the calculation is based on the analysis module related to equation 1.
Defect detection: based on the obtained data, the control unit of the device is configured to detect defects based on the stress data, compared to previously derived boundary conditions. Possible causes of defects during the soldering process may be due to positioning of the electrodes of the soldering apparatus at the edges, however are not limited thereto, and the parameters considered by the control unit for simulation include current from one end to the other, contact of the heat source electrode and heating caused by resistance, soldering time (about 3 s), solder melting point of about 180 ℃. Referring to fig. 5 (b), which shows a connector design with a soldering electrode positioned at the edge, fig. 5 (c) discloses the heat distribution on the solder material at the end of the soldering process.
Some observations in the data obtained from the imaging unit as depicted with reference to the figures may include black areas showing unmelted areas, uneven heat distribution, the possibility of uneven distribution of solder material, which may lead to additional stress build-up, and also note that the lowest temperature on the solder material is 157 ℃. The cause of defects in the soldering process may be due to incorrect positioning of the soldering system, which results in holes in the solder due to overheating at the corners. Fig. 5 (d) shows a connector with hole locations due to incorrect positioning of the system. Fig. 5 (e) shows the temperature on the solder at the end of 3s and the corresponding temperature distribution on the face 1 of the glass and the corresponding stress developed on the glass surface. The temperature of the face 1 of the vehicle glazing is below 50 c, which is a deviation from normal conditions. The required alarm indication is provided during this process and the vehicle glazing is isolated for further viewing.
No defects were detected: consider now the second scenario, where no defects are identified, based on the stress data compared to derived boundary conditions. Consider the case of soldering of a symmetrical antenna connector, where the average temperature on face 1 is 79 ℃ and the maximum temperature of the solder material is 249 ℃ maximum, which is greater than 183 ℃ (the melting point of Sn-Pb). Here, no deviation from normal was found. After 12 hours of cooling, the maximum stress on the glass is 106Mpa, which is still at its limit (this value is usually expected to be <140Mpa for glass). Referring to fig. 6 (a), an image of the symmetrical location of the solder joints on the connector is shown. Fig. 6 (b) depicts the temperature on the solder material and the corresponding temperature distribution on the face 1 of the glass, and the corresponding stress developed on the glass surface. 100Mpa is the compressive stress on the surface of the tempered glass and, in addition, the maximum tensile strength of the glass. For simulations with a power symmetric design, it has been observed that as the temperature increases by 10 ℃, the stress decreases by 22%, the maximum temperature on face 1 is 93 ℃ and the maximum temperature of the solder material is 308 ℃. Fig. 6 (c) shows the temperature distribution on the surface 1 and the solder material thus obtained, and the stress formed on the glass under a symmetrical power simulation.
With the disclosed invention, the stress measurement system is in-line and stress measurement is performed by using photoelastic or optical birefringence methods to determine stress variations in the process. The apparatus and system relate to multi-criteria optimization of the welding process, such as, but not limited to, temperature data (transient, gradient, time), current data, HD image data. The disclosed solution uses imaging data or sensing data as input to a self-learning algorithm to improve predictability of defective glass identification and/or to provide an optimized control signal for the process based on reference data. This is advantageous for defect identification by inspecting the surface of the bus bar or the welded area prior to the welding process.
Some advantages of the invention are as follows:
the disclosed invention provides an online process for monitoring a welding process on a vehicle glazing, and the welding can be controlled with minimal human intervention, and welding defects can be identified even after the welding process.
A method of monitoring a welding process in real time is provided, comparing in real time the temperature and thermal stress between actual and calculated data, thereby performing a multi-criterion optimization.
The disclosed invention helps to reduce defects during the welding process using predictive methods.
The disclosed invention helps to identify glass batches and match machine or system parameters to improve +.
Controlling welding parameters, providing alarms, etc., thereby providing glass traceability.
Note that not all of the activities described above in the general description or the examples are required, that a portion of a specific activity may not be required, and that one or more other activities may be performed in addition to those described. Further, the order in which the activities are listed is not necessarily the order in which the activities are performed.
Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. The benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced, however, are not to be construed as a critical, required, or essential feature of any or all the claims.
The description and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The description and illustrations are not intended to serve as an exhaustive and comprehensive description of all of the elements and features of apparatus and systems that employ structures or methods described herein. For clarity, certain features described herein in the context of separate embodiments may also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in sub-combinations. Furthermore, references to values stated in ranges include each value within the range. Many other embodiments will be apparent to those of skill in the art upon reading this specification. Other embodiments may be utilized and derived from the disclosure, such that structural, logical substitutions, or other changes may be made without departing from the scope of the disclosure. Accordingly, the present disclosure should be considered as illustrative and not restrictive.
The description in connection with the figures is provided to aid in understanding the teachings disclosed herein, is provided to aid in describing the teachings, and should not be construed as limiting the scope or applicability of the teachings. However, other teachings may of course be used in this application.
As used herein, the terms "comprises," "comprising," "includes," "including," "has," "having," "has" or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited to only those features, but may include other features not expressly listed or inherent to such method, article, or apparatus. Furthermore, unless expressly stated to the contrary, "or" means an inclusive or, rather than an exclusive or. For example, the condition a or B satisfies any one of the following conditions: a is true (or present) and B is false (or absent), a is false (or absent) and B is true (or present), and both a and B are true (present).
Furthermore, the use of "a" or "an" is used to describe the elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. The specification should be understood to include one or at least one, and the singular also includes the plural and vice versa, unless explicitly stated otherwise. For example, when a single item is described herein, more than one item may be used in place of a single item. Similarly, if more than one item is described herein, more than one item may be substituted for the item.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The materials, methods, and examples are illustrative only and not intended to be limiting. Without describing certain details regarding specific materials and processing acts, such details may include conventional methods, which may be found in the referenced books and other sources of the manufacturing arts.
While aspects of the present disclosure have been particularly shown and described with reference to the foregoing embodiments, those skilled in the art will understand that various additional embodiments may be contemplated by modifying the disclosed machines, systems, and methods without departing from the spirit and scope of the disclosure. Such embodiments should be construed as falling within the scope of the present disclosure as determined based on the claims and any equivalents thereof.
List of reference numerals and corresponding features appearing in the drawings:
101: sensor for detecting a position of a body
102: data acquisition system
103. 203, 312: control unit
104: alarm unit
105. 205, 315: storage device/server
201: sensing unit 201
202: data acquisition subsystem 202
204: actuation unit
311: imaging unit 311
3121: data acquisition system
3123: actuator controller
313: actuator with a spring
315: visualization of
3122: processing unit
S101-S107: method steps
Claims (17)
1. An apparatus (100) for determining defects in a vehicle glazing, wherein the apparatus comprises:
-a plurality of sensors (101), the plurality of sensors (101) being configured to obtain at least a temperature, an image of one or more connection areas on the vehicle glazing during a welding process on the vehicle glazing;
a data acquisition system (102), the data acquisition system (102) and the plurality of sensors being operably configured for obtaining data from the sensors;
-a control unit (103), the control unit (103) comprising a processing unit, the processing unit and the data acquisition system being operably configured for analyzing the occurrence of defects during the welding process based on an analysis module; and
an alarm unit (104), the alarm unit (104) and the control unit being operably configured for providing an alarm when the occurrence of a defect is detected.
2. The apparatus of claim 1, wherein the control unit (103) is configured to: defect identification is performed by inspecting the surface of the welded area or a connection thereof on the vehicle glazing prior to or during the welding process.
3. The apparatus of claim 2, wherein the analysis of defect identification is based on: a solder material in contact with a surface of a substrate of the vehicle glazing and a solder material in contact with a connector subjected to the soldering process; and
sensor fusion data acquired from the plurality of sensors for optimal detection of defects in a vehicle glazing.
4. A device according to claim 3, wherein the inspection of the surface is identified by a stress on the surface of the substrate of the vehicle glazing, wherein stress is given by:
wherein,,
f is the force acting on the area a of the surface of the substrate;
Δt is the difference between the maximum temperature involved and room temperature;
α1 is the coefficient of thermal expansion of the solder material;
α2 is the coefficient of thermal expansion of the surface in contact with the solder material;
e1 is the Young's modulus of the solder material; and
e2 is the young's modulus of the surface in contact with the solder material.
5. The apparatus of claim 4, wherein the analysis module for analyzing the occurrence of defects in a vehicle glazing during the welding process comprises a sensor fusion data process that takes into account instantaneous and historical data of parameters for inspecting the surface of the substrate of a vehicle glazing.
6. The apparatus of claim 1, wherein the plurality of sensors (101) comprises at least an imaging unit (311), the imaging unit (311) comprising a High Definition (HD) camera and a thermal camera configured for image acquisition and analysis of a welding process, and the imaging unit being positioned such that a field of view of the unit coincides with the welding process performed on the vehicle glazing to obtain a temperature parameter through the glazing; and is also provided with
The plurality of sensors (101) further includes a power sensor configured to monitor a supply of electrical power on one or more elements performing the welding process.
7. The apparatus of claim 6, wherein the thermal camera is configured to have the HD camera imaging output as an input parameter for association with the thermal camera to identify defects during welding.
8. The apparatus of claim 6, wherein the thermal camera is optimally positioned to obtain a maximum temperature and an average temperature of the welding process.
9. The apparatus of claim 1, wherein the data acquisition system (102) is configured to obtain and further record one or more parameters associated with the vehicle glazing to enable traceability of the vehicle glazing in the event of deviations from normal conditions during the welding process.
10. The apparatus of claim 1, wherein the processing unit (3122) is configured to create a plurality of data trajectories including temperature difference tolerance, temperature distribution over the welding zone, welding duration, and power during the welding.
11. A system for adjusting a welding process in a vehicle glazing, wherein the system comprises:
-a sensing unit (201), the sensing unit (201) comprising a plurality of sensors configured to obtain at least a temperature, a power drawn, an image of one or more connection areas on the vehicle glazing during a welding process;
a data acquisition subsystem (202), the data acquisition subsystem (202) and the sensing unit being operably configured for obtaining data from the sensing unit (201);
-a control unit (203), the control unit (203) comprising a processing unit, the processing unit and the data acquisition system being operably configured for analyzing the occurrence of defects based on an analysis module; and
an actuation unit (204), the actuation unit (204) and the control unit being operably configured to: the soldering process is adjusted based on the stress caused by solder on the surface of the substrate of the vehicle glazing obtained by the analysis module.
12. The system of claim 11, wherein inspection of the surface is identified by a stress on the surface of the substrate of the vehicle glazing, wherein stress is given by:
wherein,,
f is the force acting on the area a of the surface of the substrate;
Δt is the difference between the maximum temperature involved and room temperature;
α1 is the coefficient of thermal expansion of the solder material;
α2 is the coefficient of thermal expansion of the surface in contact with the solder material;
e1 is the Young's modulus of the solder material; and
e2 is the young's modulus of the surface in contact with the solder material.
13. The system according to claim 11, wherein the sensing unit (201) is mounted on a robotic arm or gantry system in order to access a wider conveyor or for obtaining different angles with a reduced number of sensors.
14. The system of claim 11, wherein the sensing unit (201) comprises at least one imaging unit (311), the imaging unit (311) comprising a High Definition (HD) camera and a thermal camera configured for image acquisition and analysis of a welding process; and the system further includes a power sensor configured to monitor a supply of electrical power on one or more elements performing the welding process.
15. The system of claim 11, wherein the actuation unit (204) is configured to stop the welding process in case of an abnormality in the welding process.
16. The system of claim 11, wherein the analysis module for analyzing the occurrence of defects in a vehicle glazing during the welding process includes calculations made taking into account instantaneous and historical data of stress and temperature of the surface of the substrate of a vehicle glazing.
17. A method of detecting defects in a vehicle glazing during a welding process, wherein the method comprises:
obtaining (S101) an image of a surface of a substrate of a vehicle glazing from one or more sensing devices by an imaging unit, the sensing devices including a High Definition (HD) camera and a thermal camera;
preparing (S102) the obtained image by the control unit for analyzing the occurrence of defects by generating temperature and time array data;
obtaining (S103) a threshold value by the control unit for analyzing a maximum value, a minimum value, an ambient temperature, and identifying a peak temperature value based on an input from the boundary condition;
Comparing (S104), by the control unit, the temperature obtained from the sensing unit with the calculated threshold value;
if the temperature obtained from the sensing unit is greater than the threshold, initiating (S105) data recording and analyzing the occurrence of defects by a data acquisition system;
comparing (S106) the temperature of the surface of the substrate of the vehicle glazing with a reference by the control unit; and
if the obtained temperature is greater than the error margin, a signal for adjusting or stopping the welding process on the vehicle glazing is triggered (S107) by the control unit.
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| IN202041042107 | 2020-09-28 | ||
| IN202041042107 | 2020-09-28 | ||
| PCT/IN2021/050929 WO2022064519A1 (en) | 2020-09-28 | 2021-09-22 | An imaging system and a method for determining the defects in glazings |
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| BR112021011472A2 (en) * | 2019-02-28 | 2021-08-31 | Yoshino Gypsum Co., Ltd. | APPARATUS TO INSPECT PLATE-SHAPED BODIES |
| CN115082436B (en) * | 2022-07-22 | 2022-11-08 | 山东易斯特工程工具有限公司 | Shield tunneling machine tool bit production defect detection method |
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| GB0914651D0 (en) * | 2009-08-21 | 2009-09-30 | Pilkington Automotive D Gmbh | Heatable glazing inspection |
| GB201416183D0 (en) * | 2014-09-12 | 2014-10-29 | Pilkington Group Ltd | Wired glazing |
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| CN117705827A (en) * | 2024-02-06 | 2024-03-15 | 上海强华实业股份有限公司 | Method for optimizing quartz glass defect detection based on multivariable fine burning energy consumption |
| CN117705827B (en) * | 2024-02-06 | 2024-04-12 | 上海强华实业股份有限公司 | Method for optimizing quartz glass defect detection based on multivariable fine burning energy consumption |
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