JP6602707B2 - Inspection apparatus and inspection method - Google Patents

Description

  The present invention relates to an in-line defect inspection apparatus and method for manufacturing cast parts.

  For mass-produced castings such as automobile parts, it is necessary to determine the presence or absence of casting defects at the end of the casting process, and to provide a casting with no casting defects to the next machining process.

  In general, in the casting process, casting defects occur due to various factors. In particular, surface defects caused by the hot water boundary may become the starting point of fatigue cracks in an environment where an external load is applied to the object, and it is important to check for surface defects due to this hot water boundary at the end of the casting process. It is. In addition to surface defects, there is a high need for nondestructive evaluation of internal casting defects, cracks, and material defects.

JP 2013-88414 A JP-A-2015-00751

  Conventionally, in a mass production casting factory, visual inspection is performed to determine the presence / absence of surface defects due to the above-mentioned hot water boundary, the presence / absence of inclusions appearing on the surface, the loss due to mold dropping, the presence / absence of dents, and the like. On the other hand, if the production volume of the cast product increases and the production speed increases, it becomes difficult to deal with visual inspection. Therefore, an automatic defect inspection technique that replaces the visual inspection is required.

  Moreover, in general surface inspection of mass-produced products, in-line automatic inspection technology has been developed for planar objects such as electronic boards, but three-dimensionally complicated three-dimensional objects such as those found in castings for automobile parts. There are not many automatic inspection techniques for the whole surface condition of structures.

  In addition, internal casting defects other than surface defects, cracks, and defective materials are conventionally handled by destructive inspection by sampling on the production line.

  Patent Document 1 describes a three-dimensional shape inspection method and apparatus that ensures high measurement accuracy regardless of the shape of a measurement target by complementarily combining a plurality of three-dimensional shape measurement methods and surface measurement methods. This patent document 1 is effective for a three-dimensional structure having a relatively small change in shape, such as an impeller having a center of rotation axis, but mass production of automobile parts and the like targeted by this patent. It is insufficient for inspecting the entire surface of a complex structure having a large three-dimensional shape change such as a cast product.

  Further, Patent Document 2 describes a hammering inspection system for detecting internal material deterioration of a fixed structure such as a tunnel. In Patent Document 2, a hammering inspection is carried out while measuring the inside of the tunnel with a stereo camera in order to avoid obstacles in the tunnel. This system is not enough.

  In addition, in-line surface inspection at the time of production of mass-produced cast products produces a large number of cast products in a short time continuously. Therefore, in automatic surface inspection instead of visual inspection, the inspection time per piece is as short as possible. There is a need to. In the hammering test for a three-dimensional complex shape object, the acoustic characteristics generated vary depending on the hit position of the test object, so that it is necessary to accurately hit a specific position of the three-dimensional shape. On the other hand, the cast product is inferior to the machined product in terms of the dimensions and installation accuracy of the sand mold and core used for casting, so there is a difference from the design dimension in each cast product, and the specific position of the three-dimensional shape is accurately determined. In order to hit, it is necessary to grasp the three-dimensional shape of each object.

  Therefore, the subject of the present invention is made in the background as described above, and surface defects and internal defects and material defects of mass-produced cast products having a three-dimensional complicated shape are non-destructive surface defect inspection. An object of the present invention is to provide a method and an apparatus for inspecting accurately and efficiently by evaluating an internal situation defect by hitting sound.

  An inspection apparatus according to the present invention that solves the above problems includes a surface measurement unit that measures a surface of an inspection object, a sound inspection unit that performs a sound inspection of the inspection object, and measurement information from the surface measurement unit. Based on this, the relative position between the reference position of the striking member of the hammering inspection unit and the installation reference position of the inspection object is changed.

  An inspection method according to the present invention that solves the above-described problem is to measure the surface of an inspection object, and based on the measurement information from the surface measurement data, the reference position of the striking member of the sound inspection unit and the inspection object Change the relative position with the installation reference position.

  In addition to preventing oversight and judgment mistakes during conventional visual inspections, mass defects can be detected without any omission by detecting all internal defects, cracks and material defects that were handled by sampling. Casting can be produced.

It is the outline | summary of the manufacturing line system for implementing the test | inspection of a present Example. It is a block block diagram of an inspection apparatus. It is a block diagram of the inspection process with respect to one to-be-inspected object including the inspection method of a present Example. FIG. 4 is a block diagram of a process for calculating control data 104 in the block diagram of FIG. 3. FIG. 2 is a block diagram of a process for performing a hammering test in a hammering test unit 22 in the system configuration diagram of FIG. 1. It is a figure showing an example of hitting position information. It is a figure which shows the example which calculated hitting position information from the surface shape measurement data. FIG. 2 is an enlarged view of a hitting inspection unit 10 in FIG. 1. It is the outline | summary of the manufacturing line system for implementing the test | inspection in another Example.

  Embodiments of the present invention will be described below with reference to the drawings.

  FIG. 1 is an outline of a production line system for carrying out the inspection of this embodiment. FIG. 2 is a block diagram of the inspection apparatus.

  The conveyance path 2 conveys the structure 1 to be inspected from the production line and pays out after the inspection.

  The first measuring machine 3 images the surface to be inspected. The first grip 4 is capable of gripping the measurement target and rotating in a direction perpendicular to the axis. The first scanning unit 5 scans the first gripping unit 4 so as to extract the measurement target from the transport path 2 and return the measurement target.

  The second measuring device 6 images the surface to be inspected under measurement conditions different from those of the first measuring device 3.

  The second gripping unit 7 can grip the measurement target with an axis different from that of the first gripping unit 4 and can rotate in the orthogonal direction. The second scanning unit 8 scans the second gripping unit 7 so as to extract the measurement target from the transport path 2 and return the measurement target.

  The third scanning unit 9 extracts the measurement object from the conveyance path 2 and scans the structure 1 at the sound hitting position of the sound hitting inspection unit 22 shown in FIG. The hammering inspection apparatus 10 includes a hammering unit 11 that strikes a designated position of the structure 1.

  The design shape data input unit 14 shown in FIG. 2 reads design information and the like from the design shape data 13 shown in FIG. The setting unit 15 sets a striking reference position for determining a striking position for striking the structure 1 to be inspected from the design information.

  The first surface measurement unit 16 operates the first measurement device 3, the first gripping unit 4, and the first scanning unit 5 to acquire measurement data. The first data storage unit 17 stores the obtained measurement data.

  The second surface measuring unit 18 operates the second measuring machine 6, the second gripping unit 7, and the second scanning unit 8 to acquire measurement data. The second second data storage unit 19 stores the obtained measurement data.

  The determining unit 20 compares the measurement data obtained by the first surface measuring unit 16 and the second surface measuring unit 18 with the design shape data, and determines the hitting position in the sound inspection apparatus 10. The control unit 21 sets the structure 1 and the sound inspection device at the hitting position obtained by the determination unit 20. The hammering inspection unit 22 strikes the structure 1 in the set arrangement.

  The third data storage unit 23 stores the result obtained by the hammering test. The determination result processing unit 24 calculates an inspection result from the obtained surface measurement data and hammering inspection data.

  The display unit 25 displays the result of the determination result processing unit 24. The fourth data storage unit 26 stores the processing result.

  The setting unit 15, the first surface measurement unit 16, the second surface measurement unit 18, and the first data storage unit 17, the second data storage unit 19, and the third data storage unit 23 of measurement data obtained by these measurements. The determination unit 20, the control unit 21, and the measurement result processing unit 24 are included in the data storage / analysis process and the display device 12.

  FIG. 3 is a block diagram of an inspection process for one inspection object including the inspection method of this embodiment.

  In S101, when the structure 1 is paid out from the manufacturing line before the inspection is started, the inspection is started in S102.

  In S <b> 103, the structure 1 that is being transported on the transport path 2 is extracted from the transport line by driving the first scanning unit 5 and the first gripping unit 4. The operations of the first scanning unit 5 and the first gripping unit 4 at this time are defined by the input of control data 104.

  Next, in S <b> 105, the shape of the surface of the structure 1 is measured using the first measuring device 3 while the first scanning unit 5 and the first gripping unit 4 are being driven. The measurement result is sent as shape measurement data 106 to the shape measurement result calculation step in S115.

  The structure 1 that has finished the shape measurement step S105 is subjected to measurement object posture conversion in S107.

  Thereafter, in S108, the surface shape of the structure 1 is measured by the first measuring instrument 3 while the first scanning unit 5 and the first gripping unit 4 are being driven. The measured shape measurement data 106 is sent to the shape measurement result calculation step in S115.

  In S <b> 109, the structure 1 is returned to the transport path 2 by driving the first scanning unit 5 and the first gripping unit 4.

  Next, in S <b> 110, the structure 1 that is being transported on the transport path 2 is extracted from the transport line by driving the second scanning unit 8 and the second gripping unit 7. The operations of the second scanning unit 8 and the second gripping unit 7 at this time are defined by the input of the control data 104.

  In S <b> 111, the shape of the surface of the structure 1 is measured using the second measuring device 6 while the second scanning unit 8 and the second gripping unit 7 are being driven. The measurement result is sent as shape measurement data 106 to the shape measurement result calculation step in S115.

  The structure 1 that has finished the shape measurement step S111 is subjected to measurement object posture conversion in S112.

  Thereafter, in S113, the surface shape of the structure 1 is measured by the second measuring device 6 while the second scanning unit 8 and the second gripping unit 7 are being driven. The measured shape measurement data 106 is sent to the shape measurement result calculation step in S115.

  In S <b> 114, the structure 1 is returned to the transport path 2 by driving the second scanning unit 8 and the second gripping unit 7.

  Before and after S114, in S115, the surface shape measurement result of the structure 1 is calculated from the shape measurement data 106 sent from each step, and the process proceeds to the shape determination step in S116.

  In the shape determination step in S116, the shape data 119 of the structure 1 is compared with the surface shape measurement result in S115 to determine whether or not the shape is acceptable.

  If it is determined to be acceptable, the S117 surface inspection ends and the process proceeds to the hammering inspection step. If it is determined to be unacceptable, the process proceeds to S118 defective product carrying step.

  FIG. 4 is a block diagram of a process for calculating the control data 104 in the block diagram of FIG.

  In S120, the design data 121 stored in the design shape data input unit 14 is extracted. The contents of the design data 121 include, for example, shape data and a solid number to be inspected such as CAD information and model number information described in product design information.

  The retrieved design data 121 is read into the setting unit 15 in the design data reading step of S123.

  In S124, measurement conditions for each measuring machine, each gripper, and each scanning unit are set, and in S125, a measurement area to be inspected is calculated.

  In S126, it is determined whether or not there is a blind spot area other than the measurement area on the surface to be inspected. If it is determined that there is no blind spot area, the process proceeds to S129, and each measuring machine, each gripper, Measurement conditions for each scanning unit are determined. If it is determined that there is a blind spot area, the flow proceeds to S126, and it is determined whether the blind spot area is minimum. If it is determined that the blind spot area is the minimum, the process proceeds to S129, and the measurement conditions of each measuring machine, each gripping unit, and each scanning unit are determined. If it is determined that the blind spot area is not the minimum, the measurement condition is changed in S128, and the process returns to the measurement area calculation step in S125.

  The above steps are repeated until it is determined in S126 that there is no blind spot area, or it is determined in S127 that the blind spot area is minimum, and the process proceeds to the measurement condition determination step of S129. The determined measurement conditions of each measuring machine, each gripping unit, and each scanning unit are stored in the second data storage unit 19 as control data 104, read from the data storage unit in each step of FIG. The operation of each measuring machine, each gripping unit, and each scanning unit is controlled.

  FIG. 5 is a block diagram of a process for performing a sound hit inspection by the sound check unit 22 in the system configuration diagram of FIG.

  In S130, the design data 121 stored in the design shape data input unit 14 is extracted. The contents of the design data 121 include information on the design dimensions of the striking position of the striking portion 11 by the sound striking device 10 with respect to the structure 1 in addition to the above-described contents.

  FIG. 6A shows an example of the hitting position information. In order to show the center position Od of the cylindrical portion of a part of the structure 1 as the hitting position, the distance (Lx) d from the side surface in the X direction in the drawing and the distance (Ly) d from the side surface in the Y direction in the drawing are , It is included in the design data 121 as hitting position information. In addition, a plurality of hitting position information is included in the design data 121 according to the three-dimensional feature amount of each part of the structure 1.

  The extracted design data 121 is read into the setting unit 15 in the design data reading step of S131.

  Next, in S132, the surface shape measurement data 106 obtained by the first surface measurement unit 16 and the second surface measurement unit 18 in FIG. 1 and stored in the first data storage unit 17 and the second data storage unit 19 is stored. Take out.

  In S133, the feature amount of the hitting position of the hitting unit 11 by the sound hitting device 10 is calculated from the read surface shape measurement data 106.

  FIG. 6B shows an example in which hitting position information is calculated from the surface shape measurement data 106. In order to show the center position Om of the corresponding cylindrical part on the measurement data corresponding to the center position Od of the part of the cylindrical part of the structure 1 set by the design information of FIG. The distance (Lx) m from the side and the distance (Ly) m from the side surface in the Y direction in the figure are calculated from the measurement data.

  In S134, (Lx) d and (L) indicate the hitting position Od in the design data 121 corresponding to (Lx) m and (Ly) m indicating the hitting position Om of the sounding device 10 calculated from the surface shape measurement data 106. Ly) A difference amount of d is calculated.

  Based on the obtained difference amount, in S135, the hitting position of the hitting unit 11 by the hitting device 10 is set to the center position Om of the cylindrical portion of the structure 1 by moving the hitting device 10 or the structure 1. .

  When the position setting is completed, in step S136, the hitting unit 11 is operated to perform hitting sound measurement.

  Based on the obtained hammering sound measurement data 122, the hammering result is determined in S137. If it is unacceptable, it is carried out as a defective product in S139, and if it is acceptable, the inspection completion is paid out in S138.

  FIG. 7 shows an enlarged view of the hammering inspection unit 10 in FIG. The moving direction of the sounding device 10 or the structure 1 when the sounding device 10 of S135 shown in the flow of FIG. 5 is set to the hitting position of the hitting portion 11 and the center position Om of the cylindrical portion of the structure 1. showed that. When a plurality of hitting positions are set, the hitting device 10 or the structure 1 is moved a plurality of times and set to predetermined hitting positions, and hitting is performed at each position to perform a hitting test.

  An embodiment of an inspection method and apparatus for mass production castings according to the present invention is shown in FIG. In the present embodiment, in addition to the configuration of the first embodiment, a process for positioning by two positions of the structure 1 is added to the positioning process when performing the hammering inspection.

  That is, the positioning device 29 is provided in front of the hammering inspection device 11 of FIG. In the positioning device 29, the hitting position setting jig 30 sets the hitting position using the processing flow shown in FIG. 5 for a plurality of positions indicating the shape characteristics of the structure 1. Thereby, the positioning accuracy is improved and the determination accuracy in the hitting test is improved.

  The present invention provides a method for efficiently constructing a defect inspection method for a mass-produced cast product having a three-dimensional complex shape by using the mass-produced cast product inspection method and apparatus of the present invention, and further, a mass-produced cast product that replaces the current visual inspection In-line surface inspection device can be provided at the time of manufacturing, and it is possible to prevent oversight and determination mistakes during conventional visual inspection, and to manufacture a mass-produced cast product with high efficiency, high quality and high reliability. At the same time, it is possible to inspect all internal defects, cracks, and material defects in-line by hitting the whole number.

DESCRIPTION OF SYMBOLS 1 ... Structure, 2 ... Conveyance path, 3 ... 1st measuring machine, 4 ... 1st holding part, 5 ... 1st scanning part, 6 ... 2nd measuring machine, 7 ... 2nd gripping part, 8 ... 2nd scanning part, 9 ... 3rd investigation part, 10 ... Sound-inspecting device, 11 ... Striking part, 12 ... Data storage , Analysis processing and display device, 13 ... design shape data, 14 ... design shape data input unit, 15 ... setting unit, 16 ... first surface measurement unit, 17 ... first data storage Part, 18 ... second surface measurement part, 19 ... second data storage part, 20 ... determination part, 21 ... control part, 22 ... hammering inspection part, 23 ... first 3 data storage unit, 24 ... measurement result processing unit, 25 ... display unit, 26 ... fourth data storage unit, 27 ... one example of design shape data, 28 ... measurement shape data 1 example 29 ... hammering positioning device, 30 ... hammering positioning jig, S101 ... manufacturing line dispensing step, S102 ... inspection start step, S103 ... line extraction step, 104 ... control data, S105 ... shape measurement step, 106 ... shape measurement data, S107 ... measurement object posture conversion step, S108 ... shape measurement step, S109 ... line return step, S110 ... line extraction step, S111 ... Shape measurement step, S112 ... Measurement object posture conversion step, S113 ... Shape measurement step, S114 ... Line return step, S115 ... Shape measurement result calculation step, S116 ... Shape pass / fail Judgment step, S117 ... Surface inspection end step, S118 ... Defect Unloading step, 119 ... shape data, S120 ... design data fetching step, 121 ... design data, S123 ... design data reading step, S124 ... measurement condition setting step, S125 ... measurement area Calculation step, S126 ... blind spot area presence / absence determination step, S127 ... blind spot area range determination step, S128 ... measurement condition change step, S129 ... measurement condition determination step, S130 ... design data extraction step, S131 ... Design data reading step, S132 ... Surface shape measurement data reading, S133 ... Striking position and feature size calculation step from surface shape measurement data, S134 ... Measurement data and design data Difference amount calculation step, S135... Attachment position resetting step, S136 ... hammering sound measurement step, 122 ... hammering sound measurement data, S137 ... hammering sound determination step, S138 ... inspection end, payout step

Claims (11)

An inspection apparatus for inspecting a defect of an inspection object which is a three-dimensional shape casting,
The inspection apparatus includes a surface measurement unit that measures the shape of the surface of the inspection object ,
A sound inspection unit that performs a sound inspection of the inspection object ,
The surface measurement unit includes a first surface measurement unit and a second surface measurement unit that measures the surface of the inspection object in a different axial direction from the first surface measurement unit,
The inspection apparatus calculates a surface shape measurement result based on measurement information of the first surface measurement unit and the second surface measurement unit, and performs pass / fail judgment of the surface shape,
Furthermore, based on the measurement information of the first surface measurement unit and the second surface measurement unit, the relative position between the reference position of the striking member of the sound inspection unit and the installation reference position of the inspection object An inspection apparatus characterized in that the hitting position is determined by changing. The inspection apparatus according to claim 1,
An inspection apparatus having a measurement result processing unit that determines whether or not a measurement result of the inspection object satisfies a determination criterion based on measurement data obtained by the surface measurement unit and the hammering inspection unit.   The inspection apparatus according to claim 1,
  Based on the measurement information of the first surface measurement unit and the second surface measurement unit,
An inspection apparatus for evaluating a surface defect of the inspection object. The inspection apparatus according to claim 1 or 2,
A reference shape of the inspection object is preset,
An inspection apparatus that determines the hitting position based on a difference amount between the reference shape and the measurement data.   The inspection apparatus according to claim 1,
  When a blind spot area that cannot be measured by the first surface measurement unit and the second surface measurement unit is detected,
  The measurement condition of the first surface measurement unit and the second surface measurement unit is changed and measurement is continued until it is determined that the blind spot region is not present or the blind spot region is minimal. Inspection device. An inspection method for inspecting a defect of an inspection object which is a three-dimensional shape casting,
A first step of measuring the shape of the surface of the inspection object ;
A second step of inspecting the sound of the inspection object ;
The first step includes a first surface measurement step, and a second surface measurement step of measuring the surface of the inspection object in an axial direction different from that of the first surface measurement unit,
Inspecting the surface defect of the inspection object from the measurement information obtained by the first surface measurement step and the second surface measurement step,
On the basis of the measurement information, determined in the second step, by changing the relative position of the installation reference position of the reference position and the test object in droplet with members of the slapping sound inspecting unit, the striking position Inspection method characterized by performing. The inspection method according to claim 6,
An inspection method for determining whether or not a measurement result of the inspection object satisfies a determination criterion based on the measurement information and sound hit inspection data. The inspection method according to claim 6 or 7, wherein
A reference shape of the inspection object is preset,
An inspection method for determining the hitting position based on a difference amount between the reference shape and the measurement information . An inspection apparatus for inspecting a defect of an inspection object which is a three-dimensional shape casting,
A setting unit for presetting a hitting reference position for determining a hitting position for hitting an object to be inspected;
A surface measurement unit for measuring the surface of the object ;
A sound-inspecting section for inspecting the object;
Based on the measurement information from the surface measurement section as a reference position with the punching, and a determination unit that determines the only position with striking Chi for striking said object,
The surface measurement unit includes a first surface measurement unit and a second surface measurement unit that measures the surface of the object by an axis different from the first surface measurement unit,
The measurement information is calculated based on measurement results of the first surface measurement unit and the second surface measurement unit . An inspection apparatus according to claim 9, wherein
The setting unit further presets a reference shape of the object,
The determination unit is an inspection apparatus that determines the hitting position based on a difference amount between the reference shape and the measurement information. An inspection apparatus according to claim 10, wherein
The setting unit further presets a difference reference position for calculating a difference amount,
The determination unit is an inspection apparatus that determines the hitting position based on a difference amount between the difference reference position and the measurement information.

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