Sensors for Quality Control in Welding

The classical inspection methods used for detecting and finding disturbances in welding process are based on direct measurement of its parameters as arc voltage, welding current, wire feed speed, etc. Using these inspection methods implies sensors insertion around the welding process and its presence could alter the metallic transference behavior and consequently an uneven quality as well as it can increase the production cost. For reducing these implications is necessary using a non intrusive inspection method. In this paper we will show nonintrusive methods to the weld quality inspection. These methods are based on sensor fusion, the extraction of global information coming from the interrelation data given by each sensor that, for example, sensing the spectroscopy radiation emission, the acoustic sensing of the electrical arc, the infrared emissions indicating the heat content of the weld. Finally, the fusion data will be applied to a statistical control for detecting and finding welding disturbances. The results will show that sensor fusion could be used as a tool to measure indirectly the weld quality in the GMAW process

Inspection System And Method For Bond Detection And Validation Of Surface Mount Devices Using Sensor Fusion And Active Perception

A hybrid surface mount component inspection system which includes both vision and infrared inspection techniques to determine the presence of surface mount components on a printed wiring board, and the quality of solder joints of surface mount components on printed wiring boards by using data level sensor fusion to combine data from two infrared sensors to obtain emissivity independent thermal signatures of solder joints, and using feature level sensor fusion with active perception to assemble and process inspection information from any number of sensors to determine characteristic feature sets of different defect classes to classify solder defects.Georgia Tech Research Corporatio

Non-destructive ultrasonic measurements of case depth

Two ultrasonic methods for nondestructive measurements of the depth of a case-hardened layer in steel are described. One method involves analysis of ultrasonic waves diffused back from the bulk of the workpiece. The other method involves finding the speed of propagation of ultrasonic waves launched on the surface of the work. Procedures followed in the two methods for measuring case depth are described

A Non-Intrusive GMA Welding Process Quality Monitoring System Using Acoustic Sensing

Most of the inspection methods used for detection and localization of welding disturbances are based on the evaluation of some direct measurements of welding parameters. This direct measurement requires an insertion of sensors during the welding process which could somehow alter the behavior of the metallic transference. An inspection method that evaluates the GMA welding process evolution using a non-intrusive process sensing would allow not only the identification of disturbances during welding runs and thus reduce inspection time, but would also reduce the interference on the process caused by the direct sensing. In this paper a nonintrusive method for weld disturbance detection and localization for weld quality evaluation is demonstrated. The system is based on the acoustic sensing of the welding electrical arc. During repetitive tests in welds without disturbances, the stability acoustic parameters were calculated and used as comparison references for the detection and location of disturbances during the weld runs

Automation of painted slate inspection

This thesis is concerned with the problem of how to detect visual defects on painted slates using an automated visual inspection system. The vision system that has been developed consists of two major components. The first component addresses issues such as the mechanical implementation and interfacing the inspection system with the optical and sensing equipment whereas the second component involves the development of an image processing algorithm able to identify the visual defects present on the slate surface. The visual defects can be roughly classified into two distinct categories. In this way, substrate faults occur when the slate is not fully formed or has excess material whilst paint faults describe a slate of uneven colour or gloss level. A key element in successfully imaging the slate surface defects is the illumination set-up. After extensive testing, an effective collimated lighting topology was selected and is described in detail. Imaging the slate surface was challenging because it is dark coloured, glossy and has depth profile non-uniformities. A four component image processing algorithm was designed to detect the range of defect types. The constituent components are global mean threshold, adaptive signal threshold, labelling, edge detection and labelling. Having proven a solution on the laboratory test bed, a prototype conveyor-based inspection system was assembled in order to replicate a factory-style environment. Robustness tests were performed on 400 slates and a 97% success rate was achieved. This thesis is concluded with a discussion on the feasibility of progressing this project to installation on an automated production line