Systems and methods for inspecting coatings, surfaces and interfaces

• US 7,220,966 B2
• Filed: 11/12/2004
• Issued: 05/22/2007
• Est. Priority Date: 07/29/2003
• Status: Expired due to Fees

• Current Assignee: Toyota Motor Corporation, University Of Kentucky Research Foundation (University of Kentucky)
• Original Assignee: Toyota Motor Manufacturing North America (Toyota Motor Corporation)
• Inventors: Saito, Kozo, Sakakibara, Masahito, Suzuki, Toshikazu, Tanigawa, Yasuo, Hassan Ali, Mohammed I., Omar, Mohammed A., Numasato, Akira
• Primary Examiner(s): Gagliardi; Albert
• Application Number:
  US10/987,065
• Publication Number:
  US 20050186327A1
• Time in Patent Office: 921 Days
• Field of Search: 250/341.6, 250/341.1
• US Class Current: 250/341.6
• CPC Class Codes: B05B 16/20 Arrangements for spraying in combination with other operations, e.g. drying; Arrangements enabling a combination of spraying operations
• CPC Class Codes: B05D 3/0263 with IR heaters
• CPC Class Codes: B05D 5/005 Repairing damaged coatings
• CPC Class Codes: G01N 25/72 Investigating presence of flaws

Abstract

A system for detecting defects in paint coatings includes a temperature manipulation apparatus configured to change the temperature of a surface and a coating applied to the surface. The system may further include an infrared sensor for measuring the change in temperature (over time) of the surface and coating and a processor to compare the measured change in temperature of the surface and coating to an expected change of temperature (over time) in order to determine anomalies in the coatings. A self-referencing method of determining defects is also disclosed, wherein surrounding pixels are utilized as a reference in the detection process for calculating the change in temperature of each pixel. In addition, application of the inventive aspects to inspection of adhesion interfaces is also disclosed.

Claims

1. A method for detecting defects in coatings comprising the steps of:

a) applying a first coating to a surface;

b) modifying the temperature of the surface and coating;

c) creating a thermal profile for said surface and said first coating by measuring a temperature parameter at each of a plurality of localized areas;

d) for each localized areas, calculating a change parameter for the particular localized area by comparing the temperature parameter for the particular localized area to at least one value corresponding to the temperature parameters of localized areas surrounding the particular localized area, wherein the surrounding localized areas correspond to less than the entire thermal profile such that the at least one value changes dependent upon the particular localized area; and

e) locating at least one defect by identifying at least one change parameter deviating from an acceptable level.

2. The method for detecting defects in coatings as recited in claim 1, further comprising the steps of:

a) measuring a thermal profile of said surface to create a thermal signature;

b) taking a first measurement of amount of radiation emitted from said surface and said first coating;

c) comparing said radiation emitted to said thermal signature;

d) applying a second coating to said first coating;

e) creating a temperature differentiation between said surface, said first coating and a second coating;

f) taking a second measurement of amount of emitted radiation from said surface and said first and second coatings; and

g) comparing said first measurement to said second measurement.

3. The method for detecting defects in coatings as recited in claim 1, further comprising the step of identifying the three-dimensional location of said defects.

4. The method for detecting defects in coatings as recited in claim 1, further comprising the step of correcting a defect located.

5. The method for detecting defects in coatings as recited in claim 1, further comprising the step of changing, in real time, the operation of an application apparatus upon location of a defect.