WO2019098232A1 - 検査システム、制御方法、および記憶媒体 - Google Patents
検査システム、制御方法、および記憶媒体 Download PDFInfo
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- WO2019098232A1 WO2019098232A1 PCT/JP2018/042113 JP2018042113W WO2019098232A1 WO 2019098232 A1 WO2019098232 A1 WO 2019098232A1 JP 2018042113 W JP2018042113 W JP 2018042113W WO 2019098232 A1 WO2019098232 A1 WO 2019098232A1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/22—Details, e.g. general constructional or apparatus details
- G01N29/26—Arrangements for orientation or scanning by relative movement of the head and the sensor
- G01N29/265—Arrangements for orientation or scanning by relative movement of the head and the sensor by moving the sensor relative to a stationary material
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B17/00—Measuring arrangements characterised by the use of infrasonic, sonic or ultrasonic vibrations
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/04—Analysing solids
- G01N29/043—Analysing solids in the interior, e.g. by shear waves
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/04—Analysing solids
- G01N29/07—Analysing solids by measuring propagation velocity or propagation time of acoustic waves
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/22—Details, e.g. general constructional or apparatus details
- G01N29/225—Supports, positioning or alignment in moving situation
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/22—Details, e.g. general constructional or apparatus details
- G01N29/32—Arrangements for suppressing undesired influences, e.g. temperature or pressure variations, compensating for signal noise
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/01—Indexing codes associated with the measuring variable
- G01N2291/011—Velocity or travel time
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/02—Indexing codes associated with the analysed material
- G01N2291/023—Solids
- G01N2291/0234—Metals, e.g. steel
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/02—Indexing codes associated with the analysed material
- G01N2291/028—Material parameters
- G01N2291/0289—Internal structure, e.g. defects, grain size, texture
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/04—Wave modes and trajectories
- G01N2291/044—Internal reflections (echoes), e.g. on walls or defects
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/10—Number of transducers
- G01N2291/105—Number of transducers two or more emitters, two or more receivers
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/10—Number of transducers
- G01N2291/106—Number of transducers one or more transducer arrays
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/26—Scanned objects
- G01N2291/267—Welds
- G01N2291/2672—Spot welding
Definitions
- Embodiments of the present invention relate to an inspection system, a control method, and a storage medium.
- welds parts of two or more parts are melted and joined to make one member.
- the members produced by welding are inspected whether the welded parts (hereinafter referred to as welds) are properly joined.
- a probe including an ultrasonic sensor is brought into contact with the weld. Then, ultrasonic waves are transmitted toward the welds, and the presence or absence of bonding is checked based on the reflected waves.
- the angle of the probe with respect to the part influences the inspection result. For example, if the inspection is performed at an inappropriate angle, it may be determined as unjoined although it is actually properly joined. For this reason, it is desirable that the angle of the probe be set to an appropriate value.
- development of a technique capable of adjusting the angle of the probe to a more appropriate value is desired.
- the problem to be solved by the present invention is to provide an inspection system, a control method, and a storage medium capable of adjusting the angle of the probe to a more appropriate value.
- An inspection system includes a probe and a controller.
- the probe includes a plurality of ultrasonic sensors arranged in a first direction.
- the probe moves in a second direction intersecting the first direction to contact the weld.
- Each of the plurality of ultrasonic sensors transmits an ultrasonic wave toward the weld and receives a reflected wave.
- the control unit detects joining and non-joining at a plurality of points along the first direction of the weld based on the plurality of reflected waves, and joining or non-joining is detected at the plurality of points Adjusting the angle of the probe around a third direction perpendicular to the first direction and intersecting the second direction based on a number.
- FIG. 1 is a schematic view showing an inspection system according to the embodiment.
- Drawing 2 is a perspective view showing a part of inspection system concerning an embodiment.
- the inspection system 100 according to the embodiment is for nondestructive inspection of a weld where two or more parts are integrated.
- an inspection system 100 includes an inspection apparatus 1 and a control unit 2.
- the inspection apparatus 1 includes a probe 10, an imaging unit 20, an application unit 30, and a robot arm (hereinafter referred to as an arm) 40.
- the probe 10 includes a plurality of ultrasonic sensors used for inspection of welds.
- the imaging unit 20 captures the welded member and acquires an image.
- the imaging unit 20 extracts weld marks from the image and detects the position of the welds.
- the application unit 30 applies the couplant to the upper surface of the weld.
- the couplant is used to acoustically match the ultrasound between the probe 10 and the test object.
- the couplant may be liquid or gel-like.
- the probe 10, the imaging unit 20, and the application unit 30 are provided at the tip of the arm 40, for example, as shown in FIG.
- the arm 40 is, for example, an articulated robot. By driving the arm 40, the positions of the probe 10, the imaging unit 20, and the application unit 30 can be changed.
- the control unit 2 controls the operation of these components included in the inspection apparatus 1.
- the inspection apparatus 1 is connected to an apparatus including the control unit 2 by wired communication or wireless communication, for example. Or the control part 2 is provided in the test
- FIG. 3 is a schematic view showing the internal structure of the probe tip of the inspection system according to the embodiment.
- the matrix sensor 11 includes a plurality of ultrasonic sensors 12.
- the ultrasonic sensor 12 is, for example, a transducer.
- the plurality of ultrasonic sensors 12 are arranged in a first direction D1 and a third direction D3 orthogonal to each other.
- the probe 10 moves in a second direction D2 intersecting with a plane including the first direction D1 and the third direction D3 and contacts the inspection target.
- the second direction D2 is perpendicular to the plane including the first direction D1 and the third direction D3.
- FIG. 3 shows a state in which the member 5 is inspected.
- the member 5 is manufactured by spot-welding the metal plate 51 and the metal plate 52 in the welding portion 53.
- a solidified portion 54 is formed in which a part of the metal plate 51 and a part of the metal plate 52 are melted, mixed and solidified.
- Each ultrasonic sensor 12 transmits the ultrasonic wave US toward the member 5 coated with the couplant 55 and receives the reflected wave RW from the member 5.
- one ultrasonic sensor 12 transmits ultrasonic waves US toward the welding portion 53.
- a part of the ultrasonic wave US is reflected by the surface or the bottom of the member 5 or the like.
- Each of the plurality of ultrasonic sensors 12 receives and detects the reflected wave RW.
- Each ultrasonic sensor 12 sequentially transmits ultrasonic waves US, and each reflected wave RW is received by a plurality of ultrasonic sensors 12 to two-dimensionally inspect the vicinity of the weld portion 53 of the member 5.
- FIG. 4 is a flowchart showing an outline of the operation of the inspection system according to the embodiment.
- the imaging unit 20 captures an image of the member 5 and detects the position of the welding portion 53 from the acquired image (step S1).
- the arm 40 moves the application unit 30 to a position facing the welding unit 53 in the second direction D2.
- the application unit 30 applies the couplant to the weld (step S2).
- the arm 40 moves the probe 10 in the second direction D2 to contact the welding portion 53 (step S3).
- the plurality of ultrasonic sensors 12 transmit the ultrasonic wave US toward the member 5 including the welding portion 53 and receive the reflected wave RW.
- the control unit 2 adjusts the angle of the probe 10 based on the plurality of reflected waves RW (step S4).
- the plurality of ultrasonic sensors 12 inspect the welded portion 53 (step S5).
- the control unit 2 determines whether there is a weld portion 53 not inspected yet (step S6).
- step S7 If there are no untested welds 53, the test ends.
- the control unit 2 drives the arm 40 to move the probe 10, the imaging unit 20, and the application unit 30 toward another weld portion 53 (step S7). Thereafter, steps S1 to S6 are executed again.
- FIG. 5 is a schematic view for explaining an inspection method by the inspection system according to the embodiment.
- a part of the ultrasonic wave US is reflected by the upper surface 5 a of the metal plate 51 or the upper surface 5 b of the welding portion 53.
- Another part of the ultrasonic wave US is incident on the member 5 and is reflected by the bottom surface 5 c of the metal plate 51 or the bottom surface 5 d of the welding portion 53.
- the positions of the upper surface 5a, the upper surface 5b, the bottom surface 5c, and the bottom surface 5d in the second direction D2 are different from each other. That is, the distances in the second direction D2 between these surfaces and the ultrasonic sensor 12 are different from each other.
- the ultrasonic sensor 12 receives the reflected waves from these surfaces, the peak of the reflected wave intensity is detected. By calculating the time until each peak is detected after transmitting the ultrasonic wave US, it can be checked on which surface the ultrasonic wave US is reflected.
- 5 (b) and 5 (c) are graphs illustrating the relationship between the time after transmission of the ultrasonic wave US and the intensity of the reflected wave RW.
- the graph of FIG. 5B illustrates the reception result of the reflected wave RW from the top surface 5 a and the bottom surface 5 c of the metal plate 51.
- the graph of FIG. 5C illustrates the reception result of the reflected wave RW from the top surface 5 b and the bottom surface 5 d of the weld 53.
- the first peak Pe1 is based on the reflected wave RW from the upper surface 5a.
- the second peak Pe2 is based on the reflected wave RW from the bottom surface 5c.
- the times at which the peak Pe1 and the peak Pe2 are detected correspond to the positions of the top surface 5a and the bottom surface 5c of the metal plate 51 in the second direction D2, respectively.
- the time difference TD1 between the time when the peak Pe1 is detected and the time when the peak Pe2 is detected corresponds to the distance Di1 in the second direction D2 between the top surface 5a and the bottom surface 5c.
- the first peak Pe3 is based on the reflected wave RW from the upper surface 5b.
- the second peak Pe4 is based on the reflected wave RW from the bottom surface 5d.
- the times at which the peak Pe3 and the peak Pe4 are detected correspond to the positions of the top surface 5b and the bottom surface 5d of the weld 53 in the second direction D2, respectively.
- the time difference TD2 between the time when the peak Pe3 is detected and the time when the peak Pe4 is detected corresponds to the distance Di2 in the second direction D2 between the top surface 5b and the bottom surface 5d.
- the ultrasonic wave US can be detected by detecting the time until the first peak (first peak) and the second peak (second peak) of the reflected wave RW are detected.
- the position of the reflected surface in the second direction D2 can be detected. From the difference between the time when the first peak is detected and the time when the second peak is detected, the distance in the second direction D2 between the surfaces on which the ultrasonic waves US are reflected can be detected.
- FIG. 6 is a flowchart showing a method of adjusting the probe angle by the inspection system according to the embodiment.
- FIG. 7 is a diagram for explaining an inspection system according to the embodiment.
- the ultrasonic waves US are transmitted from the plurality of ultrasonic sensors 12 and the reflected waves RW are received (step S401).
- each ultrasonic sensor 12 sequentially transmits an ultrasonic wave US, and each reflected wave RW is received by a plurality of ultrasonic sensors 12.
- FIG. 7A and FIG. 7D are plan views showing the vicinity of the welding portion 53 of the member 5.
- step S401 for example, the structure in the detection area DA shown in FIG. 7A is detected. That is, bonding or non-bonding is detected at each point of the detection area DA.
- the control unit 2 adjusts the angle around the third direction D3 of the probe 10 based on the detection result on the line segment L1 along the first direction D1 among the detection results.
- the line segment L1 is located, for example, near the center of the detection area DA in the third direction D3.
- FIG. 7B is an example of the detection result at each point on the line segment L1.
- the vertical axis represents the position in the second direction D2.
- the horizontal axis represents the position in the first direction D1.
- a circle (white circle) indicates the position of the first reflection surface (first reflection surface) of the member 5 in the second direction D2. That is, ⁇ represents the position of the upper surface 5a or the position of the upper surface 5b.
- ( ⁇ ) indicates the position of the second reflection surface (second reflection surface) of the member 5 in the second direction D2. That is, ⁇ represents the position of the bottom surface 5c or the position of the bottom surface 5d.
- these positions are calculated based on the time until the peak of the reflected wave RW is detected after transmitting the ultrasonic wave US.
- ⁇ represents the detection result of bonding and non-bonding described later.
- the control unit 2 calculates the distance between the first reflection surface and the second reflection surface. For example, when the distance is equal to or greater than a predetermined threshold value, the control unit 2 determines that the point is joined. When the distance is less than the threshold, the control unit 2 determines that the point is not joined. In the graph shown in FIG. 7B, the point determined to be joined is represented by a value of 1, and the point determined to be unjoined is represented by a value of 0.
- the control unit 2 detects bonding and non-bonding at a plurality of points along the first direction D1 of the member 5 by the above-described method.
- the control unit 2 extracts the number of junctions detected (hereinafter, referred to as the number of detections) (step S402).
- the control unit 2 determines whether the number of detections is equal to or greater than a preset threshold (step S403).
- the threshold is set based on the dimension of the weld 53 in the first direction D1, the density of the ultrasonic sensor 12 in the first direction D1, and the like.
- step S5 shown in FIG. 4 may be omitted. This is because a sufficient number of detections have already been detected, and the welds 53 can be considered to be properly joined. If the number of detections is less than the threshold value, the control unit 2 compares the number m1 of steps S401 and S402 executed so far with the preset value n1 (step S404).
- step S405 If the number of times m1 is less than the value n1, the control unit 2 changes the angle around the third direction D3 of the probe 10 (step S405). Then, step S401 is executed again. Thus, steps S401 and S402 are repeatedly performed while changing the angle around the third direction D3.
- the control unit 2 derives an appropriate first angle around the third direction D3 of the probe 10 from the detection result up to that point (step S406).
- FIG. 7C shows an example of the detection result obtained by repeating steps S401 to S405.
- the horizontal axis represents the angle around the third direction D3
- the vertical axis represents the number of detections at each angle.
- the control unit 2 sets the angle ⁇ 1 at which the number of detections is the largest as the first angle.
- the control unit 2 may generate a quadratic function QF representing the relationship between the angle and the number of detections, and set the angle ⁇ 2 as the inflection point of the quadratic function QF as the first angle.
- the control unit 2 sets the angle around the third direction D3 of the probe 10 to the first angle (step S407).
- the ultrasonic waves US are transmitted from the plurality of ultrasonic sensors 12 and the reflected waves RW are received (step S408).
- each ultrasonic sensor 12 sequentially transmits an ultrasonic wave US, and each reflected wave RW is received by a plurality of ultrasonic sensors 12.
- step S408 the structure in the detection area DA is detected.
- the control unit 2 adjusts the angle of the probe 10 in the third direction D3 based on the detection result on the line segment L2 along the third direction D3 shown in FIG. 7D.
- the line segment L2 is located, for example, near the center of the detection area DA in the first direction D1.
- the control unit 2 extracts the number of detections at a plurality of points along the third direction D3 of the member 5 as in step S402 (step S409).
- the control unit 2 determines whether the number of detections is equal to or greater than a preset threshold (step S410).
- the threshold is set based on the dimension of the weld 53 in the third direction D3, the density of the ultrasonic sensor 12 in the third direction D3, and the like.
- control unit 2 If the number of detections is equal to or greater than the threshold value, the control unit 2 maintains the angle of the probe 10 around the first direction D1 and ends the angle adjustment. If the number of detections is less than the threshold, the control unit 2 compares the number m2 of steps S408 and S409 executed so far with the value n2 set in advance (step S411).
- control unit 2 changes the angle of the probe 10 around the first direction D1 (step S412). Then, steps S408 to S410 are performed again.
- control unit 2 derives an appropriate second angle around the first direction D1 of the probe 10 from the detection result up to that point (step S413). Derivation of the second angle is performed in the same manner as the method of step S406. The control unit 2 sets the angle around the first direction D1 of the probe 10 to the second angle (step S414).
- the angle of the probe 10 is appropriately adjusted, and then the inspection of the welded portion 53 by the probe 10 is performed.
- step S411 The case where the number of times m2 is equal to or more than the value n2 in step S411 indicates that the welding portion 53 has many unjoined points. This is because, although the detection is performed while changing the angle of the probe 10 in the previous steps, a sufficient number of detections has not been obtained. Therefore, in step S411, when the number of times m2 is equal to or more than the value n2, the welded portion 53 may be determined to be unjoined. In this case, the angle adjustment is completed, and step S5 shown in FIG. 4 is omitted.
- the angle of the probe 10 was adjusted using.
- the control method of angle adjustment in inspection system 100 concerning an embodiment is not limited to this.
- bonding and non-bonding detection at a plurality of points along the first direction D1 of the member 5 may be performed using only a part of the plurality of ultrasonic sensors 12 along the first direction D1.
- detection of bonding and non-bonding at a plurality of points along the third direction D3 of the member 5 may be performed using only a part of the plurality of ultrasonic sensors 12 along the third direction D3. If detection results of bonding and non-bonding at a plurality of points along a specific direction can be obtained, the specific detection method in the inspection system 100 according to the embodiment can be appropriately changed. The same applies to the control method of angle adjustment described below.
- FIG. 8 is a diagram for explaining the effect of the inspection system according to the embodiment. 8, the two horizontal axes respectively represent the angle theta D1 and the third direction D3 around the angle theta D3 around the first direction D1.
- the vertical axis represents the number of detections.
- Points P1 to P5 in FIG. 8 illustrate trajectories of changes in the number of detections when the angle ⁇ D1 and the angle ⁇ D3 are changed.
- Adjustment method of the above-mentioned angle while changing the angle theta D3 angle theta D1 and around the third direction D3 around the first direction D1, thereby achieving an increase in the number of detections.
- This method corresponds to climbing a peak of the number of detections toward a higher position, as represented by points P1 to P5 in FIG. The larger the number of detections, the more the angle of the member 5 can be inspected.
- the angles around the first direction D1 or the third direction D3 are adjusted based on the number of junctions detected at multiple points along the first direction D1 or the third direction D3 of the member 5 did.
- the inspection system 100 and the control method according to the embodiment are not limited to this example.
- the angles around the first direction D1 or the third direction D3 may be adjusted based on the number of unjoined detected at a plurality of points along the first direction D1 or the third direction D3 of the member 5 . In this case, the angle around the first direction D1 or the third direction D3 is adjusted so that the number of unjoined states is reduced.
- the angle of the probe 10 may be adjusted using the number of unjoined detections instead of the number of junctions detected.
- the angle of the probe 10 around the third direction D3 is adjusted based on the number of junctions or non junctions detected at these plurality of points.
- the inventors have found that the angle of the probe 10 around the third direction D3 can be adjusted to a more appropriate value by using this method. That is, according to the present embodiment, with respect to a probe in which a plurality of ultrasonic sensors are arranged, the angle of the probe can be adjusted to a more appropriate value.
- the control unit 2 extracts the number of detections at each angle. Then, the control unit 2 sets a first angle at which the number of detections exceeds a preset threshold as an angle around the third direction D3 of the probe 10. According to this method, it is possible to narrow the range of the angle for checking the number of detections, and to detect the more appropriate angle around the third direction D3 in a shorter time.
- the control unit 2 may change the angle around the third direction D3 of the probe 10 within the first range, and may detect the first angle at which the number of detections is largest. It may be set as an angle around the third direction D3 of ten. Alternatively, the control unit 2 may generate a quadratic function representing the relationship between the angle and the number of detections while changing the angle around the third direction D3 of the probe 10 within the first range. The control unit 2 sets a first angle, which is an inflection point of a quadratic function, as an angle around the third direction D3 of the probe 10. The first range is set in accordance with the accuracy required for the inspection of the weld portion 53.
- the wider the first range the easier it is to set to a more appropriate angle. According to these methods, it is possible to detect a more appropriate angle around the third direction D3. Alternatively, even when the number of detections in the first range is small, by generating an approximate curve of a quadratic function, the first angle at which the value of the number of detections is estimated to be large is efficiently estimated based on the quadratic function. It can be asked.
- the angle around the first direction D1 of the probe 10 is set.
- the control unit 2 extracts the number of detections at each angle while changing the angle around the first direction D1 of the probe 10 as in the case of the angle around the third direction D3.
- the control unit 2 sets an angle at which the number of detections exceeds a preset threshold as an angle around the third direction D3 of the probe 10.
- control unit 2 may set the angle at which the number of detections is the largest as the angle around the third direction D3 of the probe 10.
- control unit 2 generates a quadratic function representing the relationship between the angle and the number of detections, and sets the angle that is the inflection point of the quadratic function as the angle around the third direction D3 of the probe 10 good.
- the angle around the first direction D1 of the probe 10 and the angle around the third direction D3 are adjusted to more appropriate values.
- the angle adjustment may be performed by the following method.
- FIG. 9 is a flowchart showing another adjustment method of the probe angle by the inspection system according to the embodiment.
- FIG. 10 is a graph illustrating data detected in the inspection system according to the embodiment.
- step S401 ultrasonic waves US are sequentially transmitted from each of the ultrasonic sensors 12, and each reflected wave RW is received by the plurality of ultrasonic sensors 12 (step S421).
- FIG. 10 illustrates data detected by the plurality of ultrasonic sensors 12 arranged in the first direction D1 in step S421.
- the vertical axis represents the position in the second direction D2.
- the horizontal axis represents the position of each ultrasonic sensor 12 in the first direction D1.
- the control unit 2 calculates the first inclination around the third direction D3 of the top surface 5b or the bottom surface 5d from the detection result (step S422). For example, the control unit 2 generates a linear function LF as illustrated in FIG. 10 using only the result determined to be a bond.
- the linear function LF represents the relationship between the position in the first direction D1 and the position in the second direction D2.
- the linear function LF is generated based on the reflected wave RW on the top surface 5 b or the bottom surface 5 d. More preferably, as shown in FIG. 10, the linear function LF is generated based on the reflected wave RW on the bottom surface 5d.
- the slope of this linear function LF is taken as a first slope.
- the larger the first inclination the larger the inclination of the matrix sensor 11 about the third direction D3 with respect to the upper surface 5b or the bottom surface 5d.
- the control unit 2 detects the direction of the first tilt and the magnitude of the first tilt, and changes the angle around the third direction D3 of the probe 10 so as to correct the first tilt (step S423). For example, the control unit 2 increases the angle to be changed as the first inclination is larger.
- the correction of the inclination means that the inclination is 0 and the linear function LF is substantially parallel to the horizontal axis. Thereby, the inclination of the matrix sensor 11 with respect to the top surface 5 b and the bottom surface 5 d can be reduced.
- step S408 ultrasonic waves US are sequentially transmitted from each of the plurality of ultrasonic sensors 12 arranged in the third direction D3, and each reflected wave RW is received by the plurality of ultrasonic sensors 12 (see FIG. Step S424).
- the control unit 2 calculates the second inclination around the first direction D1 of the top surface 5b or the bottom surface 5d as in step S422 (step S425).
- the larger the second inclination the larger the inclination around the first direction D1 of the matrix sensor 11 with respect to the top surface 5b or the bottom surface 5d.
- the control unit 2 changes the second angle around the first direction D1 of the probe 10 so as to correct the second inclination as in step S423 (step S426).
- steps S425 and S426 may be executed in parallel with steps S422 and S423 based on the detection result obtained in step S421. According to this method, since step S424 mentioned above can be omitted, the time required to adjust the angle of the probe 10 can be shortened.
- At least one of the angle around the first direction D1 and the angle around the third direction D3 of the probe 10 can be adjusted to more appropriate values based on one detection result. Therefore, the number of times of detection for adjusting the angle of the probe 10 can be reduced, and the time required for the angle adjustment can be shortened.
- FIG. 11 is a flowchart showing another method of adjusting the probe angle by the inspection system according to the embodiment.
- step S401 ultrasonic waves US are sequentially transmitted from each of the plurality of ultrasonic sensors 12, and each reflected wave RW is received by the plurality of ultrasonic sensors 12 (step S441).
- the control unit 2 extracts the number of detections at a plurality of points along the first direction D1 of the member 5 (step S442).
- the control unit 2 determines whether the number of detections is equal to or greater than a preset first threshold (step S443).
- the first threshold value for example, a value of the number of detections sufficient to determine that the entire weld portion 53 is sufficiently joined is set. If the number of detections is equal to or greater than the first threshold, the angle of the probe 10 is determined to be appropriate, and the angle adjustment of the probe 10 is completed. When the number of detections is less than the first threshold, the control unit 2 determines whether the number of detections is equal to or more than the second threshold set in advance (step S444).
- the second threshold is smaller than the first threshold.
- a value of the number of detections sufficient to calculate the first slope is set as the second threshold. If the number of detections is equal to or greater than the second threshold, the first inclination is calculated (step S445) and the angle around the third direction D3 of the probe 10 is corrected to correct the first inclination, as in the flowchart shown in FIG. Adjust (step S446).
- step S447 the number m1 of steps S441 to S444 is compared with a preset value n1 (step S447). If the number of times m1 is less than the value n1, the control unit 2 changes the angle of the probe 10 around the third direction D3 (step S448). Then, step S441 is performed again. If the number of times m1 is equal to or greater than the value n1, the control unit 2 derives an appropriate first angle around the third direction D3 of the probe 10 from the detection results up to that point (step S449). The control unit 2 sets the angle around the third direction D3 of the probe 10 to the first angle (step S450).
- ultrasonic waves US are sequentially transmitted from each of the plurality of ultrasonic sensors 12, and each reflected wave RW is received by the plurality of ultrasonic sensors 12 (step S451).
- the control unit 2 extracts the number of detections at a plurality of points along the third direction D3 of the member 5 (step S452).
- the control unit 2 determines whether the number of detections is equal to or greater than a preset third threshold (step S453).
- the third threshold similarly to the first threshold, for example, a value of the number of detections sufficient for determining that the entire weld portion 53 is sufficiently joined is set. If the number of detections is equal to or greater than the third threshold, the angle of the probe 10 is determined to be appropriate, and the angle adjustment of the probe 10 is completed. If the number of detections is less than the third threshold, the control unit 2 determines whether the number of detections is equal to or greater than a preset fourth threshold (step S454).
- the fourth threshold is smaller than the third threshold.
- a value of the number of detections sufficient to calculate the second slope is set as the fourth threshold. If the number of detections is equal to or greater than the fourth threshold, the second inclination is calculated (step S455) and the angle around the first direction D1 of the probe 10 is corrected to correct the second inclination, as in the flowchart shown in FIG. Adjust (step S456).
- step S457 If the number of detections is less than the fourth threshold, the number m2 of steps S451 to S454 is compared with a preset value n2 (step S457). If the number of times m2 is less than the value n2, the control unit 2 changes the angle of the probe 10 around the first direction D1 (step S458). Then, step S451 is executed again. If the number of times m2 is equal to or greater than the value n2, the control unit 2 derives an appropriate second angle around the first direction D1 of the probe 10 from the detection result up to that point (step S459). The control unit 2 sets the angle around the third direction D3 of the probe 10 to the second angle (step S460).
- step S451 may be omitted.
- step S452 is executed based on the detection result acquired in step S441. According to this method, the time required to adjust the angle of the probe 10 can be shortened.
- An embodiment of the present invention includes the following program.
- the program comprising: In the control unit The position of each of the plurality of points in the second direction is detected based on the plurality of reflected waves at a plurality of points along the first direction of the first surface of the welding portion, The first inclination of the first surface around a third direction perpendicular to the first direction and intersecting the second direction is calculated from detection results of at least a part of the plurality of positions;
- a program for adjusting the angle of the probe around the third direction so as to correct the first inclination.
- the angle of the probe 10 can be adjusted to a more appropriate value.
- the angle of the probe 10 can be adjusted to a more appropriate value by using a program that causes the control unit 2 to execute the control method described above or a storage medium that stores the program.
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Abstract
Description
図面は模式的または概念的なものであり、各部分の厚みと幅との関係、部分間の大きさの比率などは、必ずしも現実のものと同一とは限らない。同じ部分を表す場合であっても、図面により互いの寸法や比率が異なって表される場合もある。
本願明細書と各図において、既に説明したものと同様の要素には同一の符号を付して詳細な説明は適宜省略する。
図2は、実施形態に係る検査システムの一部を表す斜視図である。
実施形態に係る検査システム100は、2つ以上の部品が一体化された溶接部を非破壊検査するためのものである。
プローブ10先端の内部には、図3に表したマトリクスセンサ11が設けられている。マトリクスセンサ11は、複数の超音波センサ12を含む。超音波センサ12は、例えば、トランスデューサである。複数の超音波センサ12は、互いに直交する第1方向D1および第3方向D3に配列されている。プローブ10は、第1方向D1および第3方向D3を含む面と交差する第2方向D2に移動し、検査対象に接触する。図3の例では、第2方向D2は、第1方向D1及び第3方向D3を含む面に対して垂直である。
まず、撮像部20が部材5を撮影し、取得した画像から溶接部53の位置を検出する(ステップS1)。アーム40は、塗布部30を、溶接部53と第2方向D2において対向する位置へ移動させる。塗布部30は、カプラントを溶接部に塗布する(ステップS2)。アーム40は、プローブ10を第2方向D2に移動させ、溶接部53に接触させる(ステップS3)。
図5(a)に表したように、超音波USの一部は、金属板51の上面5aまたは溶接部53の上面5bで反射される。超音波USの別の一部は、部材5に入射し、金属板51の底面5cまたは溶接部53の底面5dで反射する。
図6は、実施形態に係る検査システムによるプローブ角度の調整方法を表すフローチャートである。
図7は、実施形態に係る検査システムを説明するための図である。
実施形態に係る検査システム100における角度調整の制御方法は、これに限定されない。例えば、部材5の第1方向D1に沿った複数の点における接合および未接合の検出は、第1方向D1に沿った複数の超音波センサ12の一部のみを用いて行っても良い。同様に、部材5の第3方向D3に沿った複数の点における接合および未接合の検出は、第3方向D3に沿った複数の超音波センサ12の一部のみを用いて行っても良い。特定の方向に沿った複数の点における接合および未接合の検出結果が得られれば、実施形態に係る検査システム100における具体的な検出方法は、適宜変更可能である。これは、以降で説明する角度調整の制御方法についても同様である。
図8において、2つの横軸は、それぞれ、第1方向D1まわりの角度θD1および第3方向D3まわりの角度θD3を表している。縦軸は、検出数を表している。図8における点P1~点P5は、角度θD1および角度θD3を変化させたときの検出数の変化の軌跡を例示している。
上述した通り、実施形態に係る検査システム100では、溶接部53の第1方向D1に沿った複数の点における接合および未接合が検出される。そして、これらの複数の点において接合または未接合が検出された数に基づいて、第3方向D3まわりにおけるプローブ10の角度が調整される。発明者らは、この方法を用いることで、プローブ10の第3方向D3まわりにおける角度をより適切な値に調整できることを発見した。すなわち、本実施形態によれば、複数の超音波センサが配列されたプローブについて、当該プローブの角度をより適切な値に調整できる。
第1範囲は、溶接部53の検査に求められる精度に応じて設定される。典型的には、第1範囲が広いほど、より適切な角度に設定され易くなる。これらの方法によれば、さらに適切な第3方向D3まわりの角度を検出できる。
または、第1範囲内における検出回数が少ない場合でも、二次関数の近似曲線を生成することで、その二次関数に基づいて検出数の値が大きいと推定される第1角度を効率的に求めることができる。
図9は、実施形態に係る検査システムによるプローブ角度の別の調整方法を表すフローチャートである。
図10は、実施形態に係る検査システムにおいて検出されたデータを例示するグラフである。
まず、ステップS401と同様、超音波センサ12のそれぞれから順次超音波USを送信し、それぞれの反射波RWを複数の超音波センサ12で受信する(ステップS421)。
図11は、実施形態に係る検査システムによるプローブ角度の別の調整方法を表すフローチャートである。
制御部に、
前記複数の超音波センサのそれぞれから前記溶接部に向けて超音波を送信して受信した複数の反射波に基づいて、前記溶接部の前記第1方向に沿った複数の点における接合および未接合を検出させ、
前記複数の点において接合または未接合が検出された数に基づいて、前記第1方向に対して垂直であり前記第2方向と交差する第3方向まわりにおける前記プローブの角度を調整させる
プログラム。
制御部に、
前記溶接部が有する第1面の前記第1方向に沿った複数の点について、前記複数の反射波に基づき、前記複数の点のそれぞれの前記第2方向における位置を検出させ、
前記複数の位置の少なくとも一部の検出結果から、前記第1方向に対して垂直であり前記第2方向と交差する第3方向まわりにおける前記第1面の第1傾斜を算出させ、
前記第1傾斜を補正するように前記第3方向まわりにおける前記プローブの角度を調整させる
プログラム。
Claims (15)
- 第1方向に配列された複数の超音波センサを含み、前記第1方向と交差する第2方向に移動して溶接部に接触するプローブであって、前記複数の超音波センサのそれぞれは、前記溶接部に向けて超音波を送信して反射波を受信する、前記プローブと、
前記複数の反射波に基づいて、前記溶接部の前記第1方向に沿った複数の点における接合および未接合を検出し、
前記複数の点において接合または未接合が検出された数に基づいて、前記第1方向に対して垂直であり前記第2方向と交差する第3方向まわりにおける前記プローブの角度を調整する
制御部と、
を備えた検査システム。 - 前記制御部は、前記プローブの前記第3方向まわりの角度を変化させながら、それぞれの角度において前記複数の点における前記数を検出し、検出された結果に基づいて、前記プローブの前記第3方向まわりにおける前記角度を設定する請求項1記載の検査システム。
- 前記制御部は、前記数が予め設定された閾値を超えた第1角度を、前記プローブの前記第3方向まわりにおける前記角度として設定する請求項2記載の検査システム。
- 前記制御部は、前記プローブの前記第3方向まわりの角度を第1範囲内で変化させ、前記数が最も多かった第1角度を、前記プローブの前記第3方向まわりにおける前記角度として設定する請求項2記載の検査システム。
- 前記制御部は、
前記プローブの前記第3方向まわりの角度を第1範囲内で変化させ、
前記角度と前記数との関係を表す二次関数を生成し、
前記二次関数の変曲点である第1角度を、前記プローブの前記第3方向まわりにおける前記角度として設定する
請求項2記載の検査システム。 - 前記超音波センサは、前記第3方向において複数配列され、
前記制御部は、さらに、
前記複数の反射波に基づいて前記溶接部の前記第3方向に沿った複数の点における接合および未接合を検出し、
前記第3方向に沿った前記複数の点における接合または未接合が検出された数に基づいて、前記第1方向まわりにおける前記プローブの角度を調整する
請求項1~5のいずれか1つに記載の検査システム。 - 第1方向に配列された複数の超音波センサを含み、前記第1方向と交差する第2方向に移動して溶接部に接触するプローブであって、前記複数の超音波センサのそれぞれは、前記溶接部に向けて超音波を送信して反射波を受信する、前記プローブと、
前記溶接部が有する第1面の前記第1方向に沿った複数の点について、前記複数の反射波に基づき、前記複数の点のそれぞれの前記第2方向における位置を検出し、
前記複数の位置の少なくとも一部の検出結果から、前記第1方向に対して垂直であり前記第2方向と交差する第3方向まわりにおける前記第1面の第1傾斜を算出し、
前記第1傾斜を補正するように前記第3方向まわりにおける前記プローブの角度を調整する
制御部と、
を備えた検査システム。 - 前記制御部は、接合が検出された前記複数の位置の前記少なくとも一部を用いて、前記第1傾斜を算出する請求項7記載の検査システム。
- 前記超音波センサは、前記第3方向において複数配列され、
前記制御部は、さらに、
前記複数の反射波に基づき、前記第1面の前記第3方向に沿った複数の点のそれぞれの前記第2方向における位置を検出し、
前記第3方向に沿った前記複数の位置の少なくとも一部の検出結果から、前記第1方向まわりにおける前記第1面の第2傾斜を算出し、
前記第2傾斜を補正するように前記第1方向まわりにおける前記プローブの角度を調整する
請求項7または8に記載の検査システム。 - 前記制御部は、前記プローブの角度を調整した後、前記溶接部に向けて前記複数の超音波センサから超音波を送信して前記溶接部を検査する請求項1~9のいずれか1つに記載の検査システム。
- 前記溶接部にカプラントを塗布する塗布部をさらに備え、
前記プローブは、前記カプラントが塗布された前記溶接部に接触する請求項1~10のいずれか1つに記載の検査システム。 - 第1方向に配列された複数の超音波センサを含むプローブを、前記第1方向と交差する第2方向において溶接部と接触させ、
前記複数の超音波センサのそれぞれから、前記溶接部に向けて超音波を送信して反射波を受信し、
前記複数の反射波に基づいて、前記溶接部の前記第1方向に沿った複数の点における接合および未接合を検出し、
前記複数の点において接合または未接合が検出された数に基づいて、前記第1方向に対して垂直であり前記第2方向と交差する第3方向まわりにおける前記プローブの角度を調整する制御方法。 - 第1方向に配列された複数の超音波センサを含むプローブを、前記第1方向と交差する第2方向において溶接部と接触させ、
前記複数の超音波センサのそれぞれから、前記溶接部に向けて超音波を送信して反射波を受信し、
前記溶接部が有する第1面の前記第1方向に沿った複数の点について、前記複数の反射波に基づき、前記複数の点のそれぞれの前記第2方向における位置を検出し、
前記複数の位置の少なくとも一部の検出結果から、前記第1方向に対して垂直であり前記第2方向と交差する第3方向まわりにおける前記第1面の第1傾斜を算出し、
前記第1傾斜を補正するように前記第3方向まわりにおける前記プローブの角度を調整する制御方法。 - 第1方向に配列された複数の超音波センサを含み、前記第1方向と交差する第2方向に移動して溶接部に接触するプローブの角度を調整するためのプログラムであって、
制御部に、
前記複数の超音波センサのそれぞれから前記溶接部に向けて超音波を送信して受信した複数の反射波に基づいて、前記溶接部の前記第1方向に沿った複数の点における接合および未接合を検出させ、
前記複数の点において接合または未接合が検出された数に基づいて、前記第1方向に対して垂直であり前記第2方向と交差する第3方向まわりにおける前記プローブの角度を調整させる
プログラムを記憶した記憶媒体。 - 第1方向に配列された複数の超音波センサを含み、前記第1方向と交差する第2方向に移動して溶接部に接触するプローブの角度を調整するためのプログラムであって、
制御部に、
前記溶接部が有する第1面の前記第1方向に沿った複数の点について、前記複数の反射波に基づき、前記複数の点のそれぞれの前記第2方向における位置を検出させ、
前記複数の位置の少なくとも一部の検出結果から、前記第1方向に対して垂直であり前記第2方向と交差する第3方向まわりにおける前記第1面の第1傾斜を算出させ、
前記第1傾斜を補正するように前記第3方向まわりにおける前記プローブの角度を調整させる
プログラムを記憶した記憶媒体。
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KR20200027019A (ko) | 2020-03-11 |
DE112018000827T5 (de) | 2019-10-31 |
EP3712608A1 (en) | 2020-09-23 |
CN110402388A (zh) | 2019-11-01 |
US20210389279A1 (en) | 2021-12-16 |
US11131652B2 (en) | 2021-09-28 |
KR20230054497A (ko) | 2023-04-24 |
CA3169429A1 (en) | 2019-05-23 |
US20200003735A1 (en) | 2020-01-02 |
EP3712608A4 (en) | 2021-08-18 |
JP6570600B2 (ja) | 2019-09-04 |
DE112018000827B4 (de) | 2023-09-07 |
KR20210144911A (ko) | 2021-11-30 |
KR102330478B1 (ko) | 2021-11-24 |
JP2019090727A (ja) | 2019-06-13 |
US11852611B2 (en) | 2023-12-26 |
CN114965715A (zh) | 2022-08-30 |
CA3072737A1 (en) | 2019-05-23 |
CA3072737C (en) | 2022-10-18 |
CN110402388B (zh) | 2022-05-24 |
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