PSO-Based Optimal Coverage Path Planning for Surface Defect Inspection of 3C Components with a Robotic Line Scanner

The automatic inspection of surface defects is an important task for quality control in the computers, communications, and consumer electronics (3C) industry. Conventional devices for defect inspection (viz. line-scan sensors) have a limited field of view, thus, a robot-aided defect inspection system needs to scan the object from multiple viewpoints. Optimally selecting the robot's viewpoints and planning a path is regarded as coverage path planning (CPP), a problem that enables inspecting the object's complete surface while reducing the scanning time and avoiding misdetection of defects. However, the development of CPP strategies for robotic line scanners has not been sufficiently studied by researchers. To fill this gap in the literature, in this paper, we present a new approach for robotic line scanners to detect surface defects of 3C free-form objects automatically. Our proposed solution consists of generating a local path by a new hybrid region segmentation method and an adaptive planning algorithm to ensure the coverage of the complete object surface. An optimization method for the global path sequence is developed to maximize the scanning efficiency. To verify our proposed methodology, we conduct detailed simulation-based and experimental studies on various free-form workpieces, and compare its performance with a state-of-the-art solution. The reported results demonstrate the feasibility and effectiveness of our approach

Feature-based hybrid inspection planning for complex mechanical parts

Globalization and emerging new powers in the manufacturing world are among many challenges, major manufacturing enterprises are facing. This resulted in increased alternatives to satisfy customers\u27 growing needs regarding products\u27 aesthetic and functional requirements. Complexity of part design and engineering specifications to satisfy such needs often require a better use of advanced and more accurate tools to achieve good quality. Inspection is a crucial manufacturing function that should be further improved to cope with such challenges. Intelligent planning for inspection of parts with complex geometric shapes and free form surfaces using contact or non-contact devices is still a major challenge. Research in segmentation and localization techniques should also enable inspection systems to utilize modern measurement technologies capable of collecting huge number of measured points. Advanced digitization tools can be classified as contact or non-contact sensors. The purpose of this thesis is to develop a hybrid inspection planning system that benefits from the advantages of both techniques. Moreover, the minimization of deviation of measured part from the original CAD model is not the only characteristic that should be considered when implementing the localization process in order to accept or reject the part; geometric tolerances must also be considered. A segmentation technique that deals directly with the individual points is a necessary step in the developed inspection system, where the output is the actual measured points, not a tessellated model as commonly implemented by current segmentation tools. The contribution of this work is three folds. First, a knowledge-based system was developed for selecting the most suitable sensor using an inspection-specific features taxonomy in form of a 3D Matrix where each cell includes the corresponding knowledge rules and generate inspection tasks. A Travel Salesperson Problem (TSP) has been applied for sequencing these hybrid inspection tasks. A novel region-based segmentation algorithm was developed which deals directly with the measured point cloud and generates sub-point clouds, each of which represents a feature to be inspected and includes the original measured points. Finally, a new tolerance-based localization algorithm was developed to verify the functional requirements and was applied and tested using form tolerance specifications. This research enhances the existing inspection planning systems for complex mechanical parts with a hybrid inspection planning model. The main benefits of the developed segmentation and tolerance-based localization algorithms are the improvement of inspection decisions in order not to reject good parts that would have otherwise been rejected due to misleading results from currently available localization techniques. The better and more accurate inspection decisions achieved will lead to less scrap, which, in turn, will reduce the product cost and improve the company potential in the market

Improvement of Geometric Quality Inspection and Process Efficiency in Additive Manufacturing

Additive manufacturing (AM) has been known for its ability of producing complex geometries in flexible production environments. In recent decades, it has attracted increasing attention and interest of different industrial sectors. However, there are still some technical challenges hindering the wide application of AM. One major barrier is the limited dimensional accuracy of AM produced parts, especially for industrial sectors such as aerospace and biomedical engineering, where high geometric accuracy is required. Nevertheless, traditional quality inspection techniques might not perform well due to the complexity and flexibility of AM fabricated parts. Another issue, which is brought up from the growing demand for large-scale 3D printing in these industry sectors, is the limited fabrication speed of AM processes. However, how to improve the fabrication efficiency without sacrificing the geometric quality is still a challenging problem that has not been well addressed. In this work, new geometric inspection methods are proposed for both offline and online inspection paradigms, and a layer-by-layer toolpath optimization model is proposed to further improve the fabrication efficiency of AM processes without degrading the resolution. First, a novel Location-Orientation-Shape (LOS) distribution derived from 3D scanning output is proposed to improve the offline inspection in detecting and distinguishing positional and dimensional non-conformities of features. Second, the online geometric inspection is improved by a multi-resolution alignment and inspection framework based on wavelet decomposition and design of experiments (DOE). The new framework is able to improve the alignment accuracy and to distinguish different sources of error based on the shape deviation of each layer. In addition, a quickest change point detection method is used to identify the layer where the earliest change of systematic deviation distribution occurs during the printing process. Third, to further improve the printing efficiency without sacrificing the quality of each layer, a toolpath allocation and scheduling optimization model is proposed based on a concurrent AM process that allows multiple extruders to work collaboratively on the same layer. For each perspective of improvements, numerical studies are provided to emphasize the theoretical and practical meanings of proposed methodologies

Computational intelligence approaches to robotics, automation, and control [Volume guest editors]

No abstract available

Ensemble Joint Sparse Low Rank Matrix Decomposition for Thermography Diagnosis System

Composite is widely used in the aircraft industry and it is essential for manufacturers to monitor its health and quality. The most commonly found defects of composite are debonds and delamination. Different inner defects with complex irregular shape is difficult to be diagnosed by using conventional thermal imaging methods. In this paper, an ensemble joint sparse low rank matrix decomposition (EJSLRMD) algorithm is proposed by applying the optical pulse thermography (OPT) diagnosis system. The proposed algorithm jointly models the low rank and sparse pattern by using concatenated feature space. In particular, the weak defects information can be separated from strong noise and the resolution contrast of the defects has significantly been improved. Ensemble iterative sparse modelling are conducted to further enhance the weak information as well as reducing the computational cost. In order to show the robustness and efficacy of the model, experiments are conducted to detect the inner debond on multiple carbon fiber reinforced polymer (CFRP) composites. A comparative analysis is presented with general OPT algorithms. Not withstand above, the proposed model has been evaluated on synthetic data and compared with other low rank and sparse matrix decomposition algorithms

Aging concrete structures: a review of mechanics and concepts

The safe and cost-efficient management of our built infrastructure is a challenging task considering the expected service life of at least 50 years. In spite of time-dependent changes in material properties, deterioration processes and changing demand by society, the structures need to satisfy many technical requirements related to serviceability, durability, sustainability and bearing capacity. This review paper summarizes the challenges associated with the safe design and maintenance of aging concrete structures and gives an overview of some concepts and approaches that are being developed to address these challenges