Visual Faris

FFully AAutomatic RRadioscopic IInspection SSystem

Automatic Defect Recognition

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Objective

Briefly describe ADR sequences, basic functions, and user-friendly interfaces

Overview previous applications Overview the abilities/limitations of the

software

Sequence of Production EventsPartstransportationand manipulation

X-ray exposure of inspection views

Digitization of X-ray images intoADR computer

Analysis of X-ray images on ADR computer

Communication of inspection results to partsunloading system

What has Visual Faris been used on?

Materials

Castings (iron, aluminum)Aluminum WheelsPistonsWelds

CustomApplications

Aluminum WheelsPistonsLDA

Views / Samples

SAMPLE 1

SAMPLE 2

SAMPLE 3

+ processing data

+ processing data

+ processing data

Wheel Inspection

View 1

View 2

View 3

Sample 1

Sample 2

Sample 3

8 Images

4 Images

4 Images

This example shows a wheel with three areas to be inspected: Rim, spokes and hub.8 images are necessary to cover the wholecircumference of the rim; only 4 images for thespokes, as they are alike; another 4 images to Cover the whole circumference of the hub. At the end of the programming the following situation should conceptually be found:

Program Overview

Operators Screen

SecurityFour levels of user accessibility

- Level 0: Access only to the operator screen and production counters

- Level 1: Access to all programming functions- Level 2: Ability to terminate the Visual Faris

session- Level 3: Ability to delete samples, Delete

working programs, Change working directory, Reset production report, Add/Delete users, Enable actions traceability, Define acceptability standards

The Programming Screen

Toolbar and menu of the main window

Command toolbar of the sample image

Sample in front is the active window

The rest of the samples are in the background,Up to 48 samples can be opened simultaneously

Visual Faris Toolbar

Basic Programming Functions

Acquisition ControlsThese are the first items addressed with

the captured image

(Low Pass Filter)Faster than integration but degrades image quality

Used with analog signals to identify and correct

The flickering caused bythe two fields

Indicates that every area with a grey level

lower than the outlined area is a defect area

Indicates that every area with a grey level

Higher than the outlined area is a defect area

Within the ROI

Region Of Interest

Up to 255/images

Multiple zones can be implemented in each ROI

Each ROI contains a criteria class that can be user defined.

Image Alignment

Roto-Transitional matching, Maximum variation from the sample image is 45

Horizontal and vertical matching

Rotational matching for wheels

Field of search

Reference Pattern

Remove Details

Raised Metal

Wheel Rim Equalize

ID Box (this will eliminate detection abilities. However, they are typically placed in non critical areas).

Mould Junctions

Ref 46&47

Region Of Processing

Up to 254 Regions can be defined per sample within the region of interest (affects processing time).

Directional and Multidirectional search engines.

Foreign Material Processing

Processing time

Location of this search engine

Areas containing edgesor high contrast featuresAnd cannot be analyzed

with this view

Regions Of Magnification

This functionality establishes a relation between pixels and distance.

4 pixels= 1mm

Optional Custom Processing

Crack Hole

Detects presence of aluminum residuals in the gallery due to a crack in the salt ring during casting.

Core Shift/ Gallery Misalignment

This function checks the centering between the salt ring and the ring carrier. The two circles represent the internal and external borders of the gallery.

Salt Residuals

This function searches for salt in the gallery that did not get flushed out during processing.

Core shift identifies where to search for salt residuals.

Regions of Belonging

This is an optional functionality developed to manage multiple parts inspections.

Different parts can be simultaneously inspected with the same working program.

Working program samples can contain different portions of different castings, each casting portion can be individually analyzed with proper processing parameters (ROP, ROM, ROI).

The acceptability standard must be the same for all castings belonging to the same working program.

Visual Faris can Analyze up to 15 castings per image.

Regions of Rejection Coding

This is an optional functionality designed to automatically label found defects.

Specific rejection codes and messages can be associated with user-definable sample areas.

Whenever a non acceptable defect shows up in a particular sample area , the rejection code and message associated with the area where the defect lies can be eventually notified to the production line.

Post Processing

Close inner points- This will fill small spaces inside the defects that have not been identified as defects themselves.

Steps of defects link- This connects close proximity defects to appear as one large defect. This is for code application where a combined length of defects is considered.

Delete single spots- Ignores defects the size of one pixel or less

Delete single lines- Ignores defects of one pixel or less that develop linearly.

Standards Definition

Results Interpretation

Defect Statistics

Image Formats Supported By Visual Faris

.bmp .tiff .raw .jpeg .rid jpeg color

Inspection Stability

Offline station can be used as a system backup Software includes a debug simulator Includes various Diagnostic tools Image quality Camera alignment Optical chain sensitivity Sample/actual image comparison Monitor test Contrast sensitivity

Simulated Defects

Implemented in the software are defects mirroring ASTM E155 code defects for use of comparison and programming.

Porosity Gas Hole Shrinkage Foreign Material (More Dense)

Porosity

Class 2 Class 3 Class 4 Class 5

Class 6 Class 7 Class 8

Gas Hole

Class 1 Class 2 Class 3 Class 4

Class 5 Class 6 Class 7 Class 8

Shrinkage

Class 1 Class 2

Class 3 Class 4

Class 5 Class 6 Class 7Class 8

Foreign Material (More Dense)

Class 1 Class 2 Class 3 Class 4

Class 5 Class 6 Class 7 Class 8

Demonstration Video

Visual Faris Advantages

Can do multiple part inspections Incorporates a virtual keyboard allowing only the need of a mouse to

program and operate Progressive toolbar layout making the software user friendly Simple and comprehensive online inspection screen Inspection images can be saved to a flash drive without disrupting

production Incorporates four levels of software access Possibility to store all information concerning inspected parts and all

data collected about defects in a MS access database Includes a classification palette that color codes defects to its

defects classification

Advantages Continued

Built in timer that shows processing and cycle times Includes an offline station that allows review of inspection images

and alterations of programming without halting production Optional multi-energy function where an image is taken at two

energies and merged to one automatically at a fast rate Effective remote support Built in ASTM based artificial defects for image analysis, testing, and

debugging Included simulator software. Allows user to simulate a production

setting using collected images. This is useful for programming and training.

Inspection system can be tailored to specific applications Industry standards can be implemented into the software (example

ASTM)

Disadvantages

Part(s) must be within a window of alignment for proper inspection

Cannot easily adapt to a laboratory setting and have cost efficiency

The software is expensive

Imaging Devices That Have Been Used With Visual Faris

Image intensifiers with either an analog camera or digital camera.

Amorphous Silicon panels with 127 micron to 400 micron pixel pitch.

Variety of different Linear Diode Arrays