WO2010044473A1 - 接合品質管理方法および接合品質管理装置 - Google Patents

接合品質管理方法および接合品質管理装置 Download PDF

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Publication number
WO2010044473A1
WO2010044473A1 PCT/JP2009/067941 JP2009067941W WO2010044473A1 WO 2010044473 A1 WO2010044473 A1 WO 2010044473A1 JP 2009067941 W JP2009067941 W JP 2009067941W WO 2010044473 A1 WO2010044473 A1 WO 2010044473A1
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WIPO (PCT)
Prior art keywords
joint
satisfied
outer peripheral
joining quality
quality control
Prior art date
Application number
PCT/JP2009/067941
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English (en)
French (fr)
Japanese (ja)
Inventor
慎一郎 角
興 水口
聡 高橋
和宏 中倉
真史 丸山
Original Assignee
日本軽金属株式会社
日軽金アクト株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Application filed by 日本軽金属株式会社, 日軽金アクト株式会社 filed Critical 日本軽金属株式会社
Priority to CN200980139980.0A priority Critical patent/CN102171552B/zh
Priority to JP2010533942A priority patent/JP5357891B2/ja
Publication of WO2010044473A1 publication Critical patent/WO2010044473A1/ja

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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84—Systems specially adapted for particular applications
    • G01N21/88—Investigating the presence of flaws or contamination
    • G01N21/95—Investigating the presence of flaws or contamination characterised by the material or shape of the object to be examined
    • G01N21/952—Inspecting the exterior surface of cylindrical bodies or wires
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
    • B23K31/125—Weld quality monitoring
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T7/00—Image analysis
    • G06T7/0002—Inspection of images, e.g. flaw detection
    • G06T7/0004—Industrial image inspection
    • G06T7/0006—Industrial image inspection using a design-rule based approach
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T7/00—Image analysis
    • G06T7/10—Segmentation; Edge detection
    • G06T7/136—Segmentation; Edge detection involving thresholding
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T2207/00—Indexing scheme for image analysis or image enhancement
    • G06T2207/30—Subject of image; Context of image processing
    • G06T2207/30108—Industrial image inspection
    • G06T2207/30164—Workpiece; Machine component

Definitions

  • the present invention relates to a joining quality control method and a joining quality control apparatus suitable for quality assurance of friction welding parts.
  • suspension parts Steel materials have been used for rod-shaped parts (hereinafter referred to as “suspension parts”) that constitute suspensions such as upper links, lower links, and radius rods. Is often used.
  • Patent Document 1 and Patent Document 2 disclose suspension parts in which an aluminum alloy end member is friction-welded to both ends of an aluminum alloy pipe-shaped member.
  • the friction welding conditions and cutting conditions are appropriately and strictly controlled, so the quality of the friction welding parts that are shipped will always satisfy the design conditions, but in order to further enhance the customer's sense of security. Therefore, it is desirable to diversify quality assurance methods.
  • an object of the present invention is to provide a joining quality control method and a joining quality control apparatus suitable for quality assurance of friction welding parts.
  • the inventor of the present application determines the quality of the friction welded part (for example, the friction welded part of the friction welded part). It has been found that there is a correlation with the fracture mode and the fracture strength at the joint interface, etc., leading to the creation of the present invention.
  • the joining quality control method according to the present invention is a joining quality control method performed on a friction welded part obtained by cutting off burrs generated on the outer peripheral side of the joint, and appeared on the outer peripheral surface of the joint.
  • the present invention it is possible to determine whether or not the quality of the friction welded parts satisfies the management standard without performing a tensile test or the like that applies a load to the final product. It is possible to guarantee the quality of all the numbers.
  • the present invention since the size of the opening area of the recess appearing on the outer peripheral surface of the joint is used as a reference, it can be objectively and quantitatively determined whether the management standard is satisfied. Therefore, the determination result is not influenced by the experience of the determiner.
  • poor welding of friction welding occurs when oxide or the like generated on the bonding surface before friction welding is not sufficiently discharged from the bonding portion as burrs. In this case, the opening area of the recess is large. It is assumed that
  • another bonding quality control method is a bonding quality control method performed on a friction welded part obtained by cutting off a burr generated on the outer peripheral side of a bonded portion, and the outer peripheral surface of the bonded portion is An imaging process for imaging, an image processing process for identifying a recess appearing on the outer peripheral surface on an image obtained in the imaging process, an area counting process for counting the area of the part specified as the recess, and joint quality Determining whether or not the management standard is satisfied, and in the determination process, when the aggregate value of the areas is equal to or less than a reference area, it is determined that the management standard is satisfied, and the area It is determined that the management standard is not satisfied when the total value is larger than the reference area.
  • another bonding quality control method is a bonding quality control method performed on a friction welded part obtained by cutting off burrs generated on the outer peripheral side of the bonded portion.
  • a dark pixel extraction process for extracting a pixel having a luminance value equal to or less than a reference luminance value from the image data obtained in the imaging process, and a pixel extracted in the dark color pixel extraction process.
  • a pixel count counting process for counting the number, and a determination process for determining whether or not the joining quality satisfies a management standard. In the determination process, when the number is equal to or less than the reference pixel number, the management standard It is determined that the management criterion is satisfied, and when the number is larger than the reference pixel number, it is determined that the management criterion is not satisfied.
  • This bonding quality control method utilizes the property that “the luminance value (density value) of the pixel that draws the concave portion is smaller than the luminance value (density value) of the pixel that draws the smooth surface around the concave portion”. It is a thing. According to this bonding quality control method, it becomes possible to determine more objectively and quantitatively whether or not the management standard is satisfied. Note that the “brightness value” in the case where the shade of a pixel is expressed by a gradation is a gradation value.
  • the stress generated in the cross section other than the bonded interface before the stress generated at the bonded interface reaches the fracture stress at the bonded interface. It is desirable to set the finished outer diameter of the joint (the outer diameter of the joint after removing the burr on the outer periphery of the joint) so that the fracture stress in the cross section is reached.
  • the imaging process may be performed after the burrs are removed so as to have the finished dimensions. In this way, it is possible to ensure that the bonding interface does not become the weakest part.
  • a joining quality control device for solving the above-mentioned problems is a joining quality control device for managing the quality of a friction welded part obtained by cutting off a burr generated on the outer peripheral side of a joining portion.
  • An image pickup means for picking up an outer peripheral surface
  • an extraction means for extracting a pixel having a luminance value equal to or less than a reference brightness value from the image data acquired by the image pickup means, and the number of pixels extracted by the extraction means
  • a determination unit that determines whether or not the joining quality satisfies a management standard, and the determination unit includes the management standard when the number is equal to or less than the reference pixel number. It is determined that the management criterion is satisfied, and when the number is larger than the reference pixel number, it is determined that the management criterion is not satisfied.
  • the joining quality control device According to the joining quality control device according to the present invention, it is possible to determine whether or not the quality of the friction welded parts satisfies the management standard without performing a tensile test or the like that applies a load to the final product. It becomes possible to guarantee the quality of all the friction welded parts.
  • the total of the opening area of the recess or the total of the number of pixels is preferably measured over the entire circumference of the joint, but can also be determined by partial measurement.
  • the quality of the friction welding parts can be assured by objective judgment criteria.
  • (A) is sectional drawing for demonstrating the structure of the friction welding part which is a test object
  • (b) is an enlarged view of the X section of (a).
  • It is a schematic diagram for demonstrating the structure of the joining quality control apparatus which concerns on embodiment of this invention.
  • It is a flowchart for demonstrating the procedure of the joining quality control method which concerns on embodiment of this invention.
  • (A) is a schematic diagram of the image imaged with the imaging means
  • (b) is a schematic diagram which shows the binary image obtained by performing the binarization process with respect to the image of (a). It is a graph which shows the relationship between the opening area of a recessed part, and a breaking load.
  • a friction welding part a joint part b burr c concave part 3 imaging means 4 extraction means 5 pixel count counting means 6 determination means
  • the joint quality control method according to the present embodiment is a joint quality control method performed on a friction welded part obtained by cutting off burrs generated on the outer peripheral side of the joint.
  • the friction welding component is a suspension rod which is a kind of suspension component
  • the application of the friction welding component is not intended to be limited.
  • the friction welding component A to be inspected is formed by friction welding the end members A2 and A2 to both ends of a pipe-like member A1.
  • the pipe-shaped member A1 and the end member A2 are both obtained by processing an extruded shape made of an aluminum alloy.
  • the type of aluminum alloy there are no particular restrictions on the type of aluminum alloy, but when the friction welded part A is used as a suspension part, it is an Al—Mg—Si based alloy that has been subjected to T6 treatment (a 6000 standard aluminum alloy of JIS standard after solution treatment). It is desirable to have a quenching treatment followed by an artificial aging treatment).
  • an Al—Mg—Si based alloy JIS standard aluminum alloy 6061-T6 treated with T6 has high strength (0.2% proof stress is 245 MPa or more) and durability (stress corrosion cracking resistance and weather resistance). It is even more desirable.
  • the finished outer diameter dimension of the joint part a (the outer diameter dimension of the joint part a after the burr b on the outer peripheral side is cut) can be set to an appropriate size, but the joint interface J does not become the weakest part. In order to guarantee that, the stress generated at the cross section other than the joint interface J reaches the fracture stress at the cross section before the stress generated at the joint interface J reaches the fracture stress at the joint interface J. It is desirable to set this.
  • the shape of the burr b changes depending on the manufacturing error of the pipe-shaped member A1 and the end member A2, the installation error on the friction welding machine, the operation error of the friction welding machine, the temperature, and the like, so that it has a predetermined finished outer diameter.
  • a concave portion (including a groove-shaped one) c may appear on the outer peripheral surface of the joint portion a after the burr b is cut off.
  • the bonding quality control method determines whether or not the bonding quality satisfies the management standard by using the size of the opening area of the recess c or various quantities correlated with the size of the opening area. To do.
  • the joint quality control device includes a component holding unit 1, a light source 2, an image pickup unit 3, an extraction unit 4, a pixel number counting unit 5, a determination unit 6, a storage unit 7, a display unit 8, a speaker 9, and the like.
  • the extraction means 4, the pixel number counting means 5, the determination means 6, the storage means 7 and the display means 8 are realized by a general-purpose computer.
  • This general-purpose computer exchanges data with a CPU (Central Processing Unit), a storage device such as RAM, ROM, and hard disk (storage unit 7), a display device such as a display (display unit 8), and an imaging unit 3. It is configured to include an interface for performing functions, and functions as the extraction unit 4, the pixel number counting unit 5, and the determination unit 6 by executing various programs stored in the storage unit 7 by the CPU.
  • a CPU Central Processing Unit
  • storage device such as RAM, ROM, and hard disk
  • display device such as a display (display unit 8)
  • an imaging unit 3 It is configured to include an interface for performing functions, and functions as the extraction unit 4, the pixel number counting unit 5, and the determination unit 6 by executing various programs stored in the storage unit 7 by the CPU.
  • the component holding means 1 is a device that rotates the friction welding component A around the central axis, and supports the chuck 11 that holds one end of the friction welding component A and the other end of the friction welding component A so as to be slidably rotatable.
  • the power source 13 includes, for example, a stepping motor or a motor with a rotary encoder (servo motor).
  • the control unit 14 acquires information (for example, an encoder signal output from a rotary encoder) regarding the rotation amount and rotation speed of the output shaft 13a of the power source 13, and outputs this to a general-purpose computer.
  • the light source 2 illuminates the joint portion a of the friction welding component A, and is disposed obliquely above the joint portion a in this embodiment.
  • the light source 2 It is desirable to use a white fluorescent lamp and white LED.
  • the imaging means 3 images the outer peripheral surface of the joint part a, and is arrange
  • the image pickup means 3 includes an image pickup device (one-dimensional image sensor) such as a CCD linear image sensor or a CMOS linear image sensor.
  • black-and-white grayscale image data (luminance (brightness) information for each pixel) is provided. Is obtained).
  • the acquired image data is output to a general-purpose computer and stored in the storage means 7. Note that an area image sensor may be used as the image sensor, and an image sensor capable of acquiring color grayscale image data may be used.
  • the extraction unit 4 has a function of extracting pixels whose luminance value (density value) is equal to or lower than the reference luminance value from the image data acquired by the imaging unit 3. Specifically, the extracting unit 4 determines whether or not the luminance value is equal to or lower than the reference luminance value for each of a large number of pixels constituting the image data, the function of reading the image data from the storage unit 7, and A function of distinguishing a pixel determined to be equal to or less than a luminance value from other pixels, a function of writing a determination result in the storage unit 7, and the like are provided.
  • the pixels that draw the recess c are smooth around the recess c.
  • the surface tends to be darker than the pixels for drawing the surface (see FIG. 4A). That is, the luminance value (density value) of the pixel that draws the concave portion c tends to be smaller than the luminance value of the pixel that draws the smooth surface around the concave portion c.
  • the reference luminance value is set to a value smaller than the luminance value of the pixel that draws the smooth surface of the joint portion a, and the luminance value less than the reference luminance value
  • the reference luminance value is preferably set to a value that does not detect fine grooves or the like that inevitably occur in the burr cutting operation.
  • the image data obtained by replacing the color of the pixel whose luminance value is larger than the reference luminance value with, for example, white (the maximum gradation value when the gradation of the pixel is expressed in gradation) is maximized. If it is created and displayed on the display means 8, the position of the pixel whose luminance value is equal to or lower than the reference luminance value can be confirmed on the screen (see FIG. 4B).
  • Pixel number counting means 5 counts the number N of pixels (hereinafter referred to as “dark color pixels”) extracted by the extracting means 4. The counting result is stored in the storage means 7.
  • Determining means 6 the friction welding quality of pressure parts is intended to determine whether to satisfy the control criterion, management criterion when the number N of the dark pixels included in the image data is equal to or less than the reference pixel number N 0 It determines that meets determines that the number N does not satisfy the management criteria is larger than the reference pixel number N 0. Since the number N of dark pixels is related to the size of the opening area of the recess c, setting the reference pixel number N 0 sets the allowable value (reference area) of the opening area of the recess c. It is none other than.
  • the reference pixel number N 0 (reference area) may be appropriately set in consideration of the performance required for the friction welding component A (breaking load and aesthetics), but the number N of dark pixels (the opening area of the recess c) It is desirable to confirm the correlation between the size) and the breaking load by a tensile test or analysis.
  • the inventor of the present application has conducted a research study on the relationship between the size of the opening area of the recess c and the quality of the friction welded part, and found that there is a correlation between them (see FIG. 5).
  • FIG. 5 is a graph showing the relationship between the opening area of the recess c (opening area obtained by measuring over the entire circumference of the joint a) and the breaking load. This graph is obtained by actually measuring the opening area and the breaking load of the suspension rod (friction welding part).
  • the suspension rod used in the test was obtained by friction welding the pipe-shaped member A1 and end members A2, A2 formed using an extruded profile (material: JIS standard aluminum alloy 6061 treated with T6). (See (a) of FIG. 1).
  • the outer diameter of the pipe-shaped member A1 and the outer diameter of the cylindrical portion of the end member A2 are both 25 mm, and the thickness of the pipe-shaped member A1 and the thickness of the cylindrical portion of the end member A2 are , Both are 4.5 (mm).
  • the burr b is cut so that the finished outer diameter of the joint a (the outer diameter of the joint a after the outer burr b is cut) is 26.5 (mm), While measuring the opening area of the recessed part c which appeared on the outer peripheral surface of the junction part a over the perimeter (1 round), the fracture
  • the image data acquired by the imaging means 3 is subjected to image processing (a pixel whose luminance value is equal to or lower than the reference luminance value is replaced with black, and a pixel whose luminance value is larger than the reference luminance value is detected.
  • the process of replacing the color with white) was performed, and the area of the black portion was measured to obtain the opening area of the recess c.
  • the breaking load was obtained by performing a tensile test after friction welding.
  • the end members A2 and A2 were gripped by the chuck of the tensile tester to apply a tensile force to the suspension rod, and the load when the suspension member broke at any point was defined as a “breaking load”.
  • the white square plot indicates that the fracture occurred at the joint interface J (friction welding surface), and the filled diamond-shaped plot indicates that the fracture occurred at other than the joint interface J. Yes.
  • the opening area in the graph of FIG. 5 is the opening area in the joint part a on the fractured side, and data is plotted with this as the horizontal axis.
  • the breaking load is greatest when the opening area is 0 (zero), the breaking load gradually decreases as the opening area increases, and decreases rapidly when the opening area exceeds a certain value. I can read. Further, when the opening area exceeds a certain value (about 1.8 (mm 2 in FIG. 5)), the fracture occurs at the joint interface J, and the joint failure at the joint interface J causes a decrease in the fracture load. I found out that The reference area (reference pixel number N 0 ) may be set so that the fracture load required for the friction welded part A can be reliably obtained in consideration of the tendency shown in FIG.
  • a horizontal line passing through the scale 85 (kN) on the vertical axis (a line segment parallel to the horizontal axis) is drawn, and the horizontal line and the graph (approximate curve)
  • a vertical line (a line segment parallel to the vertical axis) passing through the intersection is drawn, and any value below the value at the intersection of the vertical line and the horizontal axis (1.67 (mm 2 ) in FIG. 5) is used as the reference area. You only have to set it.
  • the joining quality control method according to the present embodiment will be described in detail.
  • the friction welding component A obtained by cutting off the burr b (see FIG. 1B) is held by the component holding means 1 in a state where the power source 13 is stopped.
  • the light source 2 is caused to emit light, and the illumination light is irradiated from the obliquely upper part of the joint part a of the friction welding component A toward the joint part a.
  • Imaging process S1 When the preliminary preparation is completed, the outer peripheral surface of the joint portion a is imaged while rotating the friction welding component A around the central axis. That is, a power source 13 is operated by operating a start switch (not shown) connected to the control unit 14, and the outer peripheral surface of the joint portion a is imaged by the imaging unit 3.
  • the acquired image data is stored in the storage means 7. It is desirable that the timing at which imaging is started be interlocked with the movement of the power source 13 (for example, a command pulse signal for operating the stepping motor or an encoder signal output from the rotary encoder).
  • the timing for ending the imaging may be triggered by a signal indicating that the output shaft 13a of the power source 13 has made one revolution. If the acquisition timing of the image data is synchronized with the operation of the power source 13, the amount of image data can be minimized, so that the time required for image processing can be shortened.
  • dark color pixel extraction process S2 When the imaging process S1 is completed, pixels (dark pixels) whose luminance value is equal to or less than the reference luminance value are extracted from the image data stored in the storage unit 7.
  • the extraction unit 4 reads out the image data stored in the storage unit 7, and the luminance value is less than or equal to the reference luminance value for each of a large number of pixels constituting the image data. Whether it is a dark pixel or not, and a pixel determined to be equal to or less than the reference luminance value is extracted.
  • the dark pixel extraction process may be performed on all of the acquired image data (that is, all the pixels), or a part of the image data (for example, the outer peripheral surface of the joint portion a and the joint interface J).
  • the dark pixel extraction process may be performed on the image data corresponding to the band-like region along the intersection line.
  • the pixel number counting unit 5 totals the number N of pixels determined to be dark pixels by the extracting unit 4, and stores the totaling result in the storage unit 7.
  • the determination process S4 when it is determined that “the management standard is not satisfied (failed)”, the failure is displayed on the display means 7 (see FIG. 2), or an alarm sound or the like. Is output from the speaker 9 to give a warning to the worker. Although illustration is omitted, when it is determined that “the management standard is satisfied (passed)” in the determination step S 4, the display unit 7 displays that it is passed, or outputs a chime sound or the like from the speaker 9. You can do it.
  • the joining quality control device and the joining quality control method according to the present embodiment described above whether or not the quality of the friction welded part A satisfies the management standard without performing a tensile test or the like that places a load on the final product. Therefore, it is possible to guarantee the quality of all the friction welded parts A produced.
  • the bonding quality control method according to the present embodiment the number N of dark pixels having a correlation with the opening area of the recess c is used as a reference, so whether or not the control standard is satisfied can be objectively and quantitatively determined. The determination result is not affected by the experience of the determiner.
  • the number N of dark pixels is counted to determine whether or not the management standard is satisfied.
  • the area of the portion specified as the recess c is counted. Thus, it may be determined whether or not the management standard is satisfied.
  • the area of the part specified as the recess a is totaled (area counting process). ) It is determined that the management standard is satisfied when the area total value M is equal to or less than the reference area M 0 , and the management standard is not satisfied when the area total value M is larger than the reference area M 0. You may judge.
  • the concave portion c on the image for example, binarization processing is performed on the image data acquired by the imaging unit 3 using the reference luminance value as a threshold value to generate binary image data. Good (see FIG. 4B). Further, in order to obtain the total value M of the area of the portion specified as the recess a, for example, a pixel having a luminance value of zero (or a gradation value of zero) is extracted from binary image data, The total number may be the total value M of the area.

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PCT/JP2009/067941 2008-10-17 2009-10-16 接合品質管理方法および接合品質管理装置 WO2010044473A1 (ja)

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