Porosity detection

• US 8,991,472 B2
• Filed: 09/12/2012
• Issued: 03/31/2015
• Est. Priority Date: 03/17/2008
• Status: Active Grant

• Current Assignee: Southwire Company
• Original Assignee: Southwire Company
• Inventors: Rundquist, Victor F., Dinwiddie, Ralph B. Jr.
• Primary Examiner(s): KASENGE, CHARLES R
• Application Number:
  US13/611,228
• Publication Number:
  US 20130060511A1
• Time in Patent Office: 930 Days
• Field of Search: 700/146, 702/130, 702/135, 702/136, 374/4, 374/5, 164/4.1, 164/150.1, 164/151.4, 703/2
• US Class Current: 164/150.1
• CPC Class Codes: B22D 46/00 Controlling, supervising, not restricted to casting covered by a single main group, e.g. for safety reasons controlling or regulating in general G05

Abstract

A computer executing a software algorithm may be used to detect a depression in a temperature profile. The temperature profile may be smoothed to eliminate noise. Next, the temperature profile'"'"'s center may be extracted. A polynomial may be fitted to extracted data. An algorithm used to fit the polynomial may guarantee that the fitted curve'"'"'s peak may be below the actual temperature data'"'"'s peak. Next, residuals may be calculated by subtracting the fitted curve from the actual data. If there is a dip at the center, then the residuals in the center may be less than zero. The software algorithm executing on the computer may then make a decision based on a sign of the residuals. For example, residuals less than zero may indicate bar porosity. Residuals above zero may indicate no porosity. The magnitude of the residuals may then be used to classify a size of a detected defect.

Claims

1. A system for providing porosity detection, the system comprising:

a memory storage; and

a processing unit coupled to the memory storage, wherein the processing unit is operative to;

fit a mathematical function to a heat signature profile of an object;

compare the heat signature profile to the fitted mathematical function; and

indicate that a defect exists in the object when, in response to the comparison, a peak value of the heat signature profile is less than a peak value of the mathematical function.

2. The system of claim 1, further comprising the processing unit being operative to receive, from an infrared device, data corresponding to the heat signature for the object.

3. The system of claim 1, further comprising the processing unit being operative to, in response to the indication that the defect exists in the object, slow down a casting process associated with the object.

4. The system of claim 1, wherein the processing unit being operative to fit the mathematical function to the heat signature profile comprises the processing unit being operative to fit the mathematical function comprising a polynomial.

5. The system of claim 1, wherein the processing unit being operative to fit the mathematical function to the heat signature profile comprises the processing unit being operative to fit the mathematical function comprising a second order polynomial.

6. The system of claim 1, wherein the processing unit being operative to fit the mathematical function to the heat signature profile comprises the processing unit being operative to fit the mathematical function comprising a second order mathematical function.

7. The system of claim 1, wherein the processing unit being operative to create the heat signature profile for the object comprises the processing unit being operative to create the heat signature profile comprising a natural temperature profile for the object.

8. The system of claim 1, wherein the object comprises a bar that is cast in a continuous casting process.

9. The system of claim 1, further comprising the processing unit being operative to create the heat signature profile for the object.

10. The system of claim 9, wherein the processing unit being operative to create the heat signature profile for the object comprises the processing unit being operative to create the heat signature profile for the object from a first edge of the object to a second edge of the object.

11. The system of claim 1, wherein the object comprises a casting.

12. The system of claim 11, wherein the casting comprises one of the following:

a copper casting and an aluminum casting.

13. The system of claim 1, wherein the defect comprises a void.

14. A method for providing porosity detection, the method comprising:

fitting a mathematical function to a heat signature profile of an object;

comparing, by a processor, the heat signature profile to the fitted mathematical function; and

indicating that a defect exists in the object when, in response to the comparison, a peak value of the heat signature profile is less than a peak value of the mathematical function.

15. The method of claim 14, further comprising, in response to indicating that the defect exists in the object, slowing down a casting process associated with the object.

16. The method of claim 14, further comprising creating the heat signature profile for the object.

17. The method of claim 16, wherein creating the heat signature profile for the object comprises creating the heat signature profile for the object wherein the object comprises a bar that is cast in a continuous casting process.

18. The method of claim 14, wherein the object comprises a casting.

19. The method of claim 14, wherein indicating that the defect exists comprises indicating that a void exists.

20. A non-transitory computer-readable storage medium device which stores a set of instructions which when executed performs a method for providing porosity detection, the method executed by the set of instructions comprising:

fitting a mathematical function to a heat signature profile of an object;

comparing the heat signature profile to the fitted mathematical function; and

indicating that a defect exists in the object when, in response to the comparison, a peak value of the heat signature profile is less than a peak value of the mathematical function.

21. The non-transitory computer-readable storage of claim 20, further comprising, in response to indicating that the defect exists in the object, slowing down a casting process associated with the object.

22. The non-transitory computer-readable storage of claim 20, wherein the object comprises a casting.

23. The non-transitory computer-readable storage of claim 20, wherein indicating that the defect exists comprises indicating that a void exists.

24. The non-transitory computer-readable storage of claim 20, further comprising creating the heat signature profile for the object.

25. The non-transitory computer-readable storage of claim 24, wherein creating the heat signature profile for the object comprises creating the heat signature profile for the object wherein the object comprises a bar that is cast in a continuous casting process.

26. A system for providing porosity detection, the system comprising:

a memory storage; and

a processing unit coupled to the memory storage, wherein the processing unit is operative to;

fit a mathematical function to a heat signature profile of an object;

compare the heat signature profile to the fitted mathematical function; and

indicate that a defect does not exist in the object when, in response to the comparison, a peak value of the heat signature profile is one of the following;

greater than a peak value of the mathematical function and equal to a peak value of the mathematical function.

27. The system of claim 26, further comprising the processing unit being operative to receive, from an infrared device, data corresponding to the heat signature for the object.

28. The system of claim 26, further comprising the processing unit being operative to, in response to the indication that the defect does not exist in the object, speed up a casting process associated with the object.

29. The system of claim 26, wherein the processing unit being operative to fit the mathematical function to the heat signature profile comprises the processing unit being operative to fit the mathematical function comprising a polynomial.

30. The system of claim 26, wherein the processing unit being operative to fit the mathematical function to the heat signature profile comprises the processing unit being operative to fit the mathematical function comprising a second order polynomial.

31. The system of claim 26, wherein the processing unit being operative to fit the mathematical function to the heat signature profile comprises the processing unit being operative to fit the mathematical function comprising a second order mathematical function.

32. The system of claim 26, wherein the processing unit being operative to create the heat signature profile for the object comprises the processing unit being operative to create the heat signature profile comprising a natural temperature profile for the object.

33. The system of claim 26, wherein the object comprises a bar that is cast in a continuous casting process.

34. The system of claim 26, wherein the defect comprises a void.

35. The system of claim 26, further comprising the processing unit being operative to create the heat signature profile for the object.

36. The system of claim 35, wherein the processing unit being operative to create the heat signature profile for the object comprises the processing unit being operative to create the heat signature profile for the object from a first edge of the object to a second edge of the object.

37. The system of claim 26, wherein the object comprises a casting.

38. The system of claim 37, wherein the casting comprises one of the following:

a copper casting and an aluminum casting.

39. The system of claim 26, wherein the object comprises a bar that is cast in a continuous casting process.

40. A method for providing porosity detection, the method comprising:

fitting a mathematical function to a heat signature profile of an object;

comparing, by a processor, the heat signature profile to the fitted mathematical function; and

indicating that a defect does not exist in the object when, in response to the comparison, a peak value of the heat signature profile is one of the following;

greater than a peak value of the mathematical function and equal to a peak value of the mathematical function.

41. The method of claim 40, further comprising, in response to indicating that the defect does not exist in the object, speeding up a casting process associated with the object.

42. The method of claim 40, wherein indicating that the defect does not exist comprises indicating that a void does not exist.

43. The method of claim 40, further comprising creating the heat signature profile for the object.

44. The method of claim 43, wherein creating the heat signature profile for the object comprises creating the heat signature profile for the object wherein the object comprises a bar that is cast in a continuous casting process.

45. The method of claim 40, wherein the object comprises a casting.

46. A non-transitory computer-readable storage medium device which stores a set of instructions which when executed performs a method for providing porosity detection, the method executed by the set of instructions comprising:

fitting a mathematical function to a heat signature profile of an object;

comparing the heat signature profile to the fitted mathematical function; and

indicating that a defect does not exist in the object when, in response to the comparison, a peak value of the heat signature profile is one of the following;

greater than a peak value of the mathematical function and equal to a peak value of the mathematical function.

47. The non-transitory computer-readable storage of claim 46, further comprising, in response to indicating that the defect does not exist in the object, speeding up a casting process associated with the object.

48. The non-transitory computer-readable storage of claim 46, wherein the object comprises a casting.

49. The non-transitory computer-readable storage of claim 46, wherein indicating that the defect does not exist comprises indicating that a void does not exist.

50. The non-transitory computer-readable storage of claim 46, further comprising creating the heat signature profile for the object.

51. The non-transitory computer-readable storage of claim 50, wherein creating the heat signature profile for the object comprises creating the heat signature profile for the object wherein the object comprises a bar that is cast in a continuous casting process.