WO2021176389A1 - Tête de balayage pour la détection de défauts sur des surfaces et station de détection avec ladite tête - Google Patents

Tête de balayage pour la détection de défauts sur des surfaces et station de détection avec ladite tête Download PDF

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Publication number
WO2021176389A1
WO2021176389A1 PCT/IB2021/051804 IB2021051804W WO2021176389A1 WO 2021176389 A1 WO2021176389 A1 WO 2021176389A1 IB 2021051804 W IB2021051804 W IB 2021051804W WO 2021176389 A1 WO2021176389 A1 WO 2021176389A1
Authority
WO
WIPO (PCT)
Prior art keywords
head
scanning
camera
movement
defects
Prior art date
Application number
PCT/IB2021/051804
Other languages
English (en)
Inventor
Daniel RASPONE
Marco Piloni
Original Assignee
Geico Spa
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.)
Filing date
Publication date
Application filed by Geico Spa filed Critical Geico Spa
Publication of WO2021176389A1 publication Critical patent/WO2021176389A1/fr

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Classifications

    • 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
    • G01N21/8806—Specially adapted optical and illumination features
    • 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
    • G01N21/9515—Objects of complex shape, e.g. examined with use of a surface follower device
    • 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
    • G01N21/9515—Objects of complex shape, e.g. examined with use of a surface follower device
    • G01N2021/9518—Objects of complex shape, e.g. examined with use of a surface follower device using a surface follower, e.g. robot

Definitions

  • the present invention relates to a scanning head for the detection of defects on complex surfaces, such as motor vehicle bodies.
  • the defects to be detected may be for example appearance defects on painted surfaces.
  • the defects present on the painted surfaces often have a three- dimensional character, i.e. are not simply local variations in colour, but reliefs, missing material or in any case irregularities on the surface.
  • the spatial surfaces to be scanned are defined as being "complex” since they may be a combination of concave surfaces and convex surfaces, both also with variable radii of curvature and with the presence of cusps and curvilinear connecting lines between the various parts which form the said surface.
  • a motor vehicle body may be regarded as being a complex surface since it has the aforementioned characteristics.
  • the localization of the defects on a complex surface is a fundamental step of the industrial process since it allows the tracing and any correction of the appearance defects of the product which may be noticed by the end user and which often are regarded as being an indication of the quality of the entire product.
  • the scanning head which produces the images to be processed by the detection programs, to have a sufficient spatial resolution.
  • the conventional high-resolution scanning systems such as flat scanners, must be used at a small distance from the surface to be scanned (of the order of 2-3 cm), and even in contact with the surface. These distances are, however, incompatible with the surfaces which have a complex form, such motor vehicle bodies, where the conventional concavities and projections on the surface prevent a really close movement of a conventional high-resolution scanning head.
  • the relatively low resolution offered by the known systems does not always allow precise classification and results in both classification errors and the need to use a classification system with a small number of broad defect categories.
  • the system may be unable to distinguish a small blister from a small spot where paint is missing and the two defects will therefore necessarily be included in a more general surface defect category which will probably be remedied by means of a costly repainting operation, even though in reality the blister, if correctly classified, could be removed by simply by means of a light rubbing and surface polishing operation.
  • the relatively low resolution of the known systems furthermore increase the presence of false positives, namely the indication of non-existent defects which may be due to optical imprecision, problems in the surface acquisition process, simple surface soiling, etc., conditions which in reality do not require a repair operation.
  • the object of the present invention is to provide a scanning head which allows more precise detection of defects on surfaces, also of a complex nature, such as motor vehicle bodies.
  • a scanning head for the detection of defects on surfaces of an object, intended to be moved on the surfaces of the object and comprising at least: a linear camera with recording segment which is transverse to the scanning paths so as to allow the composition of images of the surfaces by means of the sum of recording segments acquired in succession by the camera during the movement along the scanning paths; a main illuminator arranged close to the camera; two secondary illuminators arranged further away from the camera in the direction of movement along the scanning paths, with one of the two secondary illuminators arranged at the front of and the other one arranged at the rear of the camera with respect to the direction of movement along the scanning paths; the main illuminator and the secondary illuminators being arranged so as to direct their light beams such that they converge on the recording segment of the camera on a surface to be scanned.
  • the idea which has occurred is to provide a station for the detection of defects on surfaces of an object arranged in the station, comprising at least one of the scanning heads according to the invention and a positioner which moves the scanning head along paths on the surfaces of the object so as to scan these surfaces with the head.
  • FIG. 1 shows a schematic view of a station for detecting defects with the head realized according to the invention
  • FIG. 2 shows a schematic longitudinally sectioned view of the scanning head according to the invention
  • FIG. 3 shows a schematic perspective view from above of the inside of the scanning head according to Figure 2;
  • FIG. 4 shows a schematic view of the inside of the scanning head along the line IV- IV of Figure 2.
  • Figure 1 shows a station 10 realized in accordance with the invention for detecting surface defects on an object 11, for example a painted body of a motor vehicle.
  • the surfaces defects may for example comprise blisters, dents, scratches, areas where paint may be missing, or foreign bodies (threads, dust, etc.) which may be trapped in the paint, etc.
  • the station 10 may also comprises a known transport system 12 which transports in sequence the objects 11 into the station and removes them from the station at the end of the operations for detecting any defects.
  • the transport system may be a conveyor for example.
  • the transport system 12 may be a known skid conveyor where the bodies are mounted on known skids.
  • the system 10 comprises at least one scanning head 13 which is moved so as to follow suitable paths 14 (one of which is shown by way of example in Figure 1) and suitably pass along the surfaces 15 of the object 11 on which any defects are to be detected.
  • the heads 13 is moved by a suitable motorized positioner 16 which may be advantageously a robot suitably programmed to move the head automatically along the said paths above the surfaces of the object 11.
  • the robot 16 may be advantageously a known anthropomorphic robot arm, for example with six axes controllable in an interpolated manner, with the head 13 mounted on the wrist 17 of the robot.
  • the head 13 performs scanning of the surfaces 15 of the object 11 along scanning segments 18 parallel and transverse to the movement path of the head.
  • the acquisition and summing together of the scanning segments, synchronized with the movement of the positioner 16 and/or the head, may be controlled by a suitable electronic system 41 , per se substantially known and therefore not further shown or described here.
  • the electronic system 41 may also identify and classify the defects in the images produced with the movement of the head 13 using methods for processing the images known per se and therefore not further shown or described here.
  • Figure 2 shows in schematic form a partially cross-sectioned view of the inside of a head 13 realized according to the invention.
  • the head comprises a camera 20 and at least three illuminators 21 , 22 and 23.
  • the three illuminators and the cameras may have a front surface arranged substantially in the same plane which defines or is close to the scanning side 40 of the head, namely the side which faces the surface to be scanned.
  • This side may be totally open or closed by a transparent surface.
  • the camera used is advantageously of the linear type, namely is formed by light sensors arranged in a single line, so as to obtain along its optical axis, or viewing direction, an image which is formed essentially by a recording segment 24.
  • the orientation of the camera in the head is such that the recording segment 24 is arranged transverse to the scanning paths of the head. Owing to the relative movement of the head on the surface, the succession of segments 24, recorded by the camera close to one another, will allow the formation of the two-dimensional image of the scanned surface.
  • the linear camera will have its focal point on the recording segment 24 and this focal point must be made to coincide with the surface to be scanned.
  • the positioner of the station (for example positioner 16 in the station 10) will place the head at the correct distance from the surface to be scanned such that said focal point will fall on the surface of the object in the station and the recording segment 24 will coincide with the scanning segments 18 of the head which moves along the paths 14.
  • the camera will have a linear resolution of between 1000 and 4000 pixels/line (advantageously about 2666 pixels/line), a length of the recording segment 24 on the focal plane of between 3 and 6 cm, advantageously 4 cm, a heightwise resolution of between 2 and 5 microns, preferably 3 microns, with a heightwise operating range of between 1 and 4 mm, preferably about 2.6 mm.
  • the camera may be of the stereoscopic type so as to supply three- dimensional images to the system for processing and classifying the defects.
  • This allows easier classification of the defects which involve variations in height of the surface, with a clearer distinction for example between raised blisters and recesses in the painted surface.
  • the illuminators may be of the LED type, preferably cool white approx. 5500 K.
  • the Illuminators may have two types of focusing systems (for example, advantageously of the "dark field” type for excluding the area not examined by the sensor and "bright field” type for ensuring a suitable luminosity of the line, the image of which is being recorded.
  • the illuminator 21 is closest to the camera 20, while the other two illuminators 22 and 23, called secondary illuminators, are arranged further away from the camera in the direction of movement of the head along the scanning paths.
  • one of the two secondary illuminators is arranged at the front of and the other one is arranged at the rear of the camera with respect to the direction of movement of the head along its scanning paths.
  • the illuminators 21 , 22, 23 are inclined with respect to the viewing direction of the camera so as to direct their light beams such that they converge towards the recording segment 34 of the camera. Moreover, as can be clearly seen in Figures 3 and 4, the illuminators extend parallel to the recording segment 24 so as to illuminate the zone of the surface 15 in the region of the recording segment 24 of the camera.
  • the illuminators may advantageously emit light beams substantially in the form of a "blade" of light, namely with a width comparable to the length of the recording segment 24 and a thickness (in the direction transverse to the recording segment 24) much smaller than the width, but sufficient to illuminate in a substantially uniform manner the surface 15 in region of the recording segment 24 of the camera.
  • the camera will be set so as to be focused on the recording segment 24 on the surface 15 which is being scanned.
  • the light beams emitted by the three illuminators 21 , 22 and 23 intersect precisely at the recording segment 34 on the surface 15, as can be clearly seen in Figure 2.
  • axes 25, 26, 27, 28 and 29 are formed respectively by the intersection of a plane transverse to the main extension of the head (namely the plane of the drawing shown in Figure 2) with the viewing plane of the linear camera (which produces a recording segment 24 on the surface 15 to be scanned), and the planes of the blades of light emitted by the illuminators, extending parallel to the recording segment 24 and to the recording plane of the head which is defined here as the plane extending transversely with respect to the trajectory and is generally perpendicular to the surface to be scanned along the recording segment 24 (in other words, the axis 29 is the main viewing axis of the head which the positioner 16 keeps substantially perpendicular to the surface 15 during scanning).
  • the main axis 29 may be substantially perpendicular to the aforementioned scanning side 40 of the head.
  • the main illuminator 21 has been found to be particularly advantageous for the main illuminator 21 to have its main light emission axis 26 which is inclined at an angle 33 of between 10° and 60° with respect to the axis 25 of the camera and, preferably, at about 26 degrees.
  • the two secondary illuminators 22 and 23 have their respective light emission axes 27 and 28 which are oppositely inclined with respect to the axis 25 of the camera, respectively at an angle 30 of between 10° and 90°, and preferably about 39°, and an angle 31 of between 10° and 90° and preferably about 65°.
  • the secondary illuminators have their respective axes 27 and 28 which are symmetrically inclined with respect to the main axis 29, namely with an overall angle between the axes 27 and 28 which is bisected by the main axis 29.
  • the optical axis 25, or viewing direction, of the camera 20 is advantageously inclined at an angle 32 with respect to the main axis 29 of the head.
  • the angle 32 may be advantageously between 5° and 40° and preferably about 13°.
  • the inclinations of said camera 20 and the main illuminator 21 are preferably symmetrical with respect to the main axis 29 such that the angle between the axes 27 and 28 is bisected by the axis 29.
  • the head according to the invention there is a perfect scanning line which is illuminated with uniform lighting consisting essentially of the sum of the light emitted by the three illuminators and with three different inclinations of the light in the direction of movement of the head (and therefore in the direction transverse to the scanning segment 24 of the camera). It has been found that this combined illumination allows a high degree of resolution and an improved identification of the defects and categories of defects to be obtained, while also maintaining a substantial distance from the surface to be scanned. As a result it is possible to follow with the head 13 the complex surfaces of a motor vehicle body and obtain the desired high- resolution scanning necessary for suitably distinguishing between the defects on these complex surfaces. Moreover, the possibility of keeping the head at a good distance from the surface simplifies the operation of the positioner 16 which may more easily avoid interference between the scanning head and the object 11 to be scanned.
  • the optical resolution may also be only 15 microns/pixel or even less, with the head remaining at a distance from the surface 15 sufficient to avoid problems in the movements along it.
  • a station provided with the scanning head according to the invention may thus detect the defects and allow the correct classification thereof so as to indicate their position and any corrective measures with a high degree of precision.
  • the head according to the invention it is possible to distinguish between and classify with an excellent degree of precision, blisters, areas which are not uniform or have missing paint, scratches or foreign bodies which are trapped in the paint, etc., even where they have dimensions of only a few micrometres or tens of micrometres.
  • the scanning movement of the head may be obtained directly by the positioner 16 which is designed so as to be able to perform also a broad spatial movement of the head so as to position the head at the desired points on the surface of the object.
  • the positioner which performs the scanning movement may be a precision positioner with an amplitude of the movements limited to the need to scan a defect.
  • the head 13 may move with precision over a small linear distance (indicated by 44 in Figure 2) the entire scanning unit formed by the illuminators 21 , 22, 23 and the linear camera 20 in the direction transverse to the recording segment 24 (namely parallel to the scanning direction 14).
  • the movement imparted by the scanning actuator thus corresponds to a corresponding linear movement of the recording segment 24 which remains parallel to itself.
  • the scanning path 14 will thus be reduced to the small linear section 44, while the remainder of the path 14 may be also only for positioning the head on defects to be examined.
  • the linear scanning movement over the distance 44 may be obtained for example by arranging the scanning movement actuator between a housing 19 which contains the head and the positioner 16 (in particular device for fixing to the wrist 17), as indicated schematically in broken lines by 42a, or between the housing 19 and a frame 43 which supports inside the housing the head which comprises the assembly formed by the illuminators 21 , 22, 23 and the linear camera 20 (so as to move the assembly inside the housing, as schematically indicated in broken lines by 42b).
  • the scanning actuator may be of any type useful for the purpose of ensuring the precision and degree of movement, such as a linear electric actuator (also realized with a rotary motor and a suitable transmission, which may be of the female screw or rack type, for converting the rotary movement into a linear movement).
  • the positioner 16 may bring the head 13 opposite a defect (for example identified by a defect search scan performed quickly by the same head or by a special head also with a lower resolution) and the scanning movement actuator may then perform also the precision movement of the head above the defect along the limited linear scanning path so as to scan the surface with a sequence of parallel scanning lines having a resolution which may also be very high.
  • High-resolution scanning may thus be performed with precision in a relatively small rectangular area of the surface which contains the defect.
  • This allows the precise classification also of very small defects using also a positioner with a movement precision not suitable for scanning such a small size defect, but with a precision merely sufficient for positioning the head more or less above the defect.
  • the operation is speeded up by using the positioner 16 to position the head rapidly above the defect and then the positioner 44a, b (or scanning movement actuator) to perform the high-resolution scanning of only the relatively small area which contains the defect.
  • the scanning movement is performed along a precise linear axis with only a forwards and backwards movement along the direction 14 transverse to the scanning line. It is thus avoided that a possible scanning error could occur if a linear movement of the positioner 16 were to be used, i.e. a linear movement which would necessarily be interpolated owing to the plurality of movement axes which the positioner 16 must have in order to follow the progression of the complex surface of the object to be scanned and suitably position the head above this surface.
  • the precision movement of the head produced by the scanning movement actuator may have a linear travel 44 for example of between 10 and 200 mm and preferably of about 52 millimetres.
  • the displacement interval between scanning lines may be for example in a range of 0.01 mm to 1 mm and preferably around 0.1 microns.
  • the scanning speed may be for example in a range of 0.1 microns/s to 3 mm/s and preferably about 1.5 mm/s.
  • the actuator may also have a movement synchronized with the acquisition of the linear image of the camera so as to increase the quality of images which are to be acquired.
  • the synchronization may for example be performed by means of an electronic system known per se, such as the system 41 .
  • the head may have a form and/or proportions different from those shown, depending for example on the form of the cameras and the illuminators used to realize them and/or the configuration and area of the surfaces to be scanned.
  • the head may have a square plan view form rather than a rectangular one and may also have dimensions smaller than those shown in the drawings, so as to inspect for example surfaces which are smaller, with a greater concavity or within confined spaces.
  • the scanning segment of the camera (and therefore of the head) may also be more or less long depending on the extension of the surfaces and the desired scanning speed.
  • the head with several cameras and/or several illuminators arranged side-by- side in the direction transverse to the scanning paths, so as to obtain recording segments which are longer or shorter depending on the specific requirements.
  • a positioner for the head different from that shown and described by way of example may be used.
  • a Cartesian positioner or a gantry could be used, depending also on the geometrical form of the object to be scanned.
  • several scanning heads also of a different type and also supported by different positioners, may be present in the station, so as to operate in parallel and speed up the scanning operations on all the surfaces of the object to be checked.

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  • Physics & Mathematics (AREA)
  • Health & Medical Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Analytical Chemistry (AREA)
  • Biochemistry (AREA)
  • General Health & Medical Sciences (AREA)
  • General Physics & Mathematics (AREA)
  • Immunology (AREA)
  • Pathology (AREA)
  • Investigating Materials By The Use Of Optical Means Adapted For Particular Applications (AREA)
  • Length Measuring Devices By Optical Means (AREA)
  • Investigating Or Analyzing Materials By The Use Of Ultrasonic Waves (AREA)

Abstract

L'invention concerne une tête de balayage (13) pour la détection de défauts sur des surfaces (15) d'un objet (11) (notamment une carrosserie de véhicule automobile) destinée à être déplacée le long de trajectoires de balayage (14) sur les surfaces de l'objet, par exemple à l'aide d'un positionneur (16) dans une station de détection (10). La tête comprend au moins un appareil photo linéaire (20) avec un segment d'enregistrement (24) qui est transversal à la trajectoire de balayage (14) de manière à permettre la composition d'images des surfaces au moyen de la somme des segments d'enregistrement (24) acquis successivement par l'appareil photo pendant le déplacement de la tête le long des trajectoires de balayage (14). La tête comprend en outre un illuminateur principal (21) qui est disposé à proximité de l'appareil photo (20) et deux illuminateurs secondaires disposés plus loin de l'appareil photo dans la direction du mouvement de la tête le long des trajectoires de balayage, l'un des deux illuminateurs secondaires étant disposé à l'avant et l'autre à l'arrière de l'appareil photo par rapport à la direction du mouvement de la tête le long des trajectoires de balayage.
PCT/IB2021/051804 2020-03-06 2021-03-04 Tête de balayage pour la détection de défauts sur des surfaces et station de détection avec ladite tête WO2021176389A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IT102020000004786A IT202000004786A1 (it) 2020-03-06 2020-03-06 Testa di scansione per la rilevazione di difetti su superfici e stazione di rilevazione con tale testa
IT102020000004786 2020-03-06

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WO2021176389A1 true WO2021176389A1 (fr) 2021-09-10

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IT (1) IT202000004786A1 (fr)
WO (1) WO2021176389A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2023199266A1 (fr) * 2022-04-15 2023-10-19 3M Innovative Properties Company Systèmes et procédés d'inspection post-réparation d'une surface de travail
WO2024094298A1 (fr) * 2022-11-02 2024-05-10 Abb Schweiz Ag Appareil et procédé d'inspection de surface

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1450153A1 (fr) * 2001-11-30 2004-08-25 International Business Machines Corporation Dispositif d'inspection et procede d'inspection de profil de motif, systeme d'exposition
JP2007322402A (ja) * 2006-06-05 2007-12-13 Yoshiro Yamada 表面検査装置
US20100091272A1 (en) * 2008-10-10 2010-04-15 Yasunori Asada Surface inspection apparatus
WO2019239307A1 (fr) * 2018-06-12 2019-12-19 Geico Spa Procédé et installation de localisation de points sur une surface complexe dans l'espace

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1450153A1 (fr) * 2001-11-30 2004-08-25 International Business Machines Corporation Dispositif d'inspection et procede d'inspection de profil de motif, systeme d'exposition
JP2007322402A (ja) * 2006-06-05 2007-12-13 Yoshiro Yamada 表面検査装置
US20100091272A1 (en) * 2008-10-10 2010-04-15 Yasunori Asada Surface inspection apparatus
WO2019239307A1 (fr) * 2018-06-12 2019-12-19 Geico Spa Procédé et installation de localisation de points sur une surface complexe dans l'espace

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2023199266A1 (fr) * 2022-04-15 2023-10-19 3M Innovative Properties Company Systèmes et procédés d'inspection post-réparation d'une surface de travail
WO2024094298A1 (fr) * 2022-11-02 2024-05-10 Abb Schweiz Ag Appareil et procédé d'inspection de surface

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