Gradient image processing

• US 8,203,606 B2
• Filed: 11/07/2008
• Issued: 06/19/2012
• Est. Priority Date: 11/07/2008
• Status: Active Grant

• Current Assignee: Toyota Motor Engineering & Manufacturing North America Incorporated (Toyota Motor Corporation)
• Original Assignee: Toyota Motor Engineering & Manufacturing North America Incorporated (Toyota Motor Corporation)
• Inventors: Avila, Thiago I., Buse, Petru S., Walter, Joshua A. H.
• Primary Examiner(s): DOAN, DUYEN MY
• Application Number:
  US12/267,066
• Publication Number:
  US 20100118137A1
• Time in Patent Office: 1,320 Days
• Field of Search: 348/125, 348129-130, 348/88, 348/90, 348/92, 382/141, 382/149, 382/152
• US Class Current: 348/125
• CPC Class Codes: G01N 25/72 Investigating presence of flaws
• CPC Class Codes: G06T 2207/10048 Infrared image
• CPC Class Codes: G06T 2207/30136 Metal
• CPC Class Codes: G06T 7/001 using an image reference approach

Abstract

A method of assessing the quality of metal parts, for example through detection of defects in a metal part induced by processing the metal part, comprises acquiring a thermal image of the metal part after processing the metal part, determining a difference image by comparing the thermal image to a reference image, the difference image being related to temperature differences between temperature data represented by the thermal image and by the reference image, and determining a gradient image using the difference image, the gradient image representing temperature difference gradients within the difference image. An example apparatus comprises a camera, such as a thermal camera, an image processor, and an output device such as a display.

Claims

1. A method of detecting defects in a metal part arising from processing of the metal part, the method comprising:

obtaining a reference image for the metal part before processing the metal part;

acquiring a thermal image of the metal part after processing the metal part;

determining a difference image by comparing the thermal image to the reference image,

the difference image being related to temperature differences between temperature data represented by the thermal image and reference temperature data represented by the reference image;

determining a gradient image using the difference image, the gradient image representing temperature difference gradients within the difference image; and

detecting defects in the metal part

by displaying a filtered gradient image indicating regions of the metal part having a temperature difference gradient greater than a threshold value.

2. The method of claim 1, the method being a method of detecting defects in the metal part after a metal forming process.

3. The method of claim 1, the method being a method of detecting elongation defects and split defects in a stamped metal part.

4. The method of claim 1, wherein the reference image is a reference thermal image collected from a reference part after processing the reference part,

the reference part being substantially defect-free.

5. The method of claim 1, the thermal image of the metal part being acquired within 5 seconds of processing the metal part.

6. The method of claim 1, further comprising aligning the thermal image with the reference image before determining the difference image.

7. The method of claim 1, the difference image being determined by subtracting reference temperature data represented by the reference image from temperature data represented by the thermal image.

8. The method of claim 1, further

including rejecting the part if the temperature difference gradient is greater than the threshold value.

9. An apparatus for assisting the detection of defects in a metal part after processing the metal part, the apparatus comprising:

a camera, operable to acquire a thermal image of the metal part;

an image processing device, operable to compare the thermal image with a reference thermal image so as to determine a difference image,

the difference image representing temperature differences between temperatures represented by the thermal image and reference temperatures represented by the reference image,

the image processing device being further operable to determine a gradient image, the gradient image representing rates of change of temperature differences within the difference image,

and further operable to determine a filtered gradient image, the filtered gradient image indicating regions of the metal part having a temperature difference gradient greater than a threshold value; and

an output device, the output device providing a visual indication of the filtered gradient image so as to assist detection of defects within the metal part.

10. The apparatus of claim 9, the camera being a thermal camera.

11. The apparatus of claim 9, the image processing device being provided by an electronic circuit having a processor, a memory, a data input port, and a display output,

the processor being operable to execute an algorithm, the algorithm determining the gradient image from the thermal image and the reference image,

the electronic circuit receiving the thermal image from the camera using the data input port,

the reference image being stored in the memory.

12. The apparatus of claim 9, the image processing device being provided by a computer.

13. The apparatus of claim 9, wherein the output device is a display, the gradient image being shown on the display.