Process and device for detecting and evaluating surface cracks in workpieces

• US 5,047,851 A
• Filed: 02/26/1990
• Issued: 09/10/1991
• Est. Priority Date: 09/23/1987
• Status: Expired due to Fees

• Current Assignee: Ford-Werke AG (Ford Motor Company), Isotopen-Technik Dr. Sauerwein GmbH
• Original Assignee: Ford-Werke AG (Ford Motor Company), Isotopen-Technik Dr. Sauerwein GmbH
• Inventors: Schulz, Rudiger, Disselhorst, Kurt, Stolzenberg, Ekhard, Stapf, Christian, Lean, James D., Busse, Hans P., Topping, Laurence F., Kirchesch, Karl, Zindler, Wolfgang, Wiacker, Helmut, Burghoff, Herbert, Sauerwein, Kurt, Link, Rainer
• Primary Examiner(s): Kostak, Victor R.
• Application Number:
  US07/485,133
• Time in Patent Office: 561 Days
• Field of Search: 358/101, 358/106, 358/107, 382/8
• US Class Current: 382/149
• CPC Class Codes: G01N 2021/8887 based on image processing techniques
• CPC Class Codes: G01N 2021/8896 Circuits specially adapted for system specific signal conditioning
• CPC Class Codes: G01N 2021/936 Adjusting threshold, e.g. by way of moving average
• CPC Class Codes: G01N 21/91 using penetration of dyes, e.g. fluorescent ink
• CPC Class Codes: G01N 21/93 Detection standards; Calibrating baseline adjustment, drift correction
• CPC Class Codes: G01N 2201/102 Video camera
• CPC Class Codes: G01N 27/84 by applying magnetic powder or magnetic ink

Abstract

A process and device for detecting and evaluating surface cracks in workpieces wherein a picture is produced of the surface of the workpiece by means of a video camera and said picture is digitized and is processed by means of a computer to produce a binary picture of any cracks present and a sorting report is triggered when a preselected threshold level is exceeded. In order to obtain a sorting signal that is independent of the absolute brightness of the original picture a blurred background picture is derived from the original picture levels that have been converted to digitized grey shade levels and subtracted from the original picture, the difference picture formed in this way giving the crack representation. A dynamic threshold level for the sorting signal is determined by comparing the grey shade distribution of the original or the difference picture with at least one previously evaluated or difference picture and a binary picture is produced from the original or the difference picture and the grey shade threshold, and picture elements with their gray shades exceeding the set threshold are indicated as defects. The surface of the workpiece may be pre-treated by the magnetic powder or dye penetration process and/or contrast intensifying means.

Claims

1. A device for detecting and evaluating surface cracks in workpieces, comprising:

workpiece handling means for holding a workpiece;

a color television camera provided so as to view the workpiece held in the handling means, the camera having an optical filter adapted to light emanating from a crack representation agent, the camera producing a picture output including the colors red, green and blue;

a color-mixing unit connected to the camera output for mixing the colors and producing a corresponding output;

an analog-digital signal converter provided as to convert the output of the color-mixing unit;

a digital picture processing unit having a picture store, the processing unit being provided so as to receive the converted output; and

a computer unit arranged so as to prepare and evaluate digital picture levels and having a control output connected to the workpiece handling device.

3. A process according to claim 1, including subjecting the original picture to high-pass filtering so that the high-pass filtered picture gives the crack representation.

9. A process according to claim 3, including pre-treating the workpiece by at least one of a magnetic powder or dye penetration method and contrast intensifying agents.

2. A process for detecting and evaluating surface cracks in work pieces, comprising the steps of taking a picture of the surface of a workpiece with a color video camera;

masking out the background picture with a filter adapted to light emanating from a crack representation agent;

performing analog signal processing by means of a color mixing unit by mixing the colors red, green and blue in such proportions that the picture to be evaluated is a background and/or spurious signal and other signals are filtered and/or intensified;

digitized the picture;

processing the picture with a computer to produce a binary picture of any cracks present;

deriving a blurred background picture from the picture shades converted to digitized grey shade levels;

subtracting the blurred background picture from the original picture to provide a different picture which gives the crack representation; and

triggering a sorting report when a preselected threshold level is exceeded.

4. A process according to claim 2, including setting a dynamic shade threshold by comparing the grey shade distribution of one of the original and the difference picture with at least one previously evaluated picture or a difference picture, producing a binary picture from the original or the difference picture and indicating the grey shade threshold and picture elements with their grey shades above the set threshold as defects.

5. A process according to claim 4, and further including controlling a workpiece handling system when a defect is indicated to separate the workpiece concerned.

6. A process according to claim 2, including adding up a plurality of pictures converted to grey shade levels.

7. A process according to claim 2, wherein including examining at least one of the length-to-breadth ratio and the area of the picture elements of the binary picture as criterion of a crack indication.

8. A process according to claim 2, including pre-treating the workpiece by at least one of a magnetic powder or dye penetration method and contrast intensifying agents.