WO2004109268A1 - Evaluation de qualite de soudure - Google Patents

Evaluation de qualite de soudure Download PDF

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Publication number
WO2004109268A1
WO2004109268A1 PCT/SE2004/000870 SE2004000870W WO2004109268A1 WO 2004109268 A1 WO2004109268 A1 WO 2004109268A1 SE 2004000870 W SE2004000870 W SE 2004000870W WO 2004109268 A1 WO2004109268 A1 WO 2004109268A1
Authority
WO
WIPO (PCT)
Prior art keywords
weld
image
shape
data
quality
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/SE2004/000870
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English (en)
Inventor
Pavel Lemarinier
Dick Skarin
Kent Mak
Ahmed Kaddani
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Ruault-Kaddani Pascale
ABB AB
Original Assignee
Ruault-Kaddani Pascale
ABB AB
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ruault-Kaddani Pascale, ABB AB filed Critical Ruault-Kaddani Pascale
Publication of WO2004109268A1 publication Critical patent/WO2004109268A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84—Systems specially adapted for particular applications
    • G01N21/88—Investigating the presence of flaws or contamination
    • G01N21/8851—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups B23K1/00 - B23K28/00
    • B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups B23K1/00 - B23K28/00 relating to investigating the properties, e.g. the weldability, of materials
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T7/00—Image analysis
    • G06T7/0002—Inspection of images, e.g. flaw detection
    • G06T7/0004—Industrial image inspection
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T7/00—Image analysis
    • G06T7/60—Analysis of geometric attributes
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T2207/00—Indexing scheme for image analysis or image enhancement
    • G06T2207/30—Subject of image; Context of image processing
    • G06T2207/30108—Industrial image inspection
    • G06T2207/30164—Workpiece; Machine component

Definitions

  • the present invention relates generally to a device and a method for evaluation of the quality of a weld. More precisely the invention concerns a method and a system for determine a quality parameter from examining a cross section of a welded joint.
  • welding in this context should mean to unite parts of metal or plastic either by heating and allowing the parts themselves or by submitting melted material to flow together, or by hammering or press together.
  • the present invention relates to a device and a method for analyzing an image of a welded joint to evaluate the quality of the weld.
  • a quality evaluation of a welded joint cannot in general be made by an ocular inspection of the appearance of the weld. To find out the degree of penetration of the molten material, the presence of cracks or cavities, the degree of filling of added molten material and other parameters the cross section of a welded joint has to be inspected.
  • Electric arc welding is a complicated process and the resulting deposition of molten metal into a weld pool for performing the welding operation is determined by a tremendous number of interrelated and non-interrelated parameters. These parameters affect the depo- sition rate, the spatter and debris around the welding operation, the shape and appearance of the weld bead, and the location and quality of the protective slag, to name just a few.
  • the welding process is controlled by the protective gas composition, its flow rate, torch design, the welding torch angle, welding tip design, the size and shape of the deposition groove, control apparatus used in the welding process, amount of stick-out, wire feed speed, speed of the torch along the workpiece, smoke extraction, type of grounding contact on the workpiece, atmospheric conditions, the composition of the workpiece and other variables. Consequently, arc welding is largely a trial and error procedure with the ability of the welder to use the appropriate settings for obtaining consistent welds. Each time one of the parameters is changed, the appearance, size, shape, contour, chemistry and mechanical properties of the resulting weld is affected. For this reason, arc welding is a very complex science. Today trained welding engineers are required to provide the desired results. There is no procedure in the art which controls an arc welding process ad hoc without the intervention of the welder or welding engineer.
  • Arc welding systems comprising a controllable manipulator or an industrial robot are widely used in the industry.
  • the robot is programmed to follow a desired path to be welded with the welding torch being held at a specified distance.
  • the movement of the robot and the arc welding process parameters must be tuned to have optimum quality and productivity.
  • Arc welding techniques include seam and projection welding, and the type of weld includes fillet welds, butt welds and others.
  • the exemplary embodiments of the present invention disclosed are particularly useful for arc welds of the fillet weld type, but may find applications in other welding techniques and other manufacturing processes.
  • the object of the invention is to provide a systematic quality evaluation of a weld, where the influence of a human operator is minimized.
  • the evaluation process is to be performed without the need of a human operator.
  • the quality evaluation should be performed quickly, uniformly and in an accurate way. All parameters for evaluating the quality shall thus be determined automatically from an image of a cross section of a weld. Thus the pa- rameters needed for the evaluation shall be automatically measured from the image.
  • the objects are achieved by a method for evaluating the quality of a weld from an image of a cross section of a welded joint.
  • a first step the shape and position of the jointed plates and the shape and position of the weld is determined.
  • the weld in this context should include the weld bead itself as well as the melted portion of the jointed plates.
  • a template representing a predetermined shape of a desired weld is superimposed onto the weld.
  • the areas of mismatch is calculated and used for the quality evaluation.
  • the contours of the jointed plates and their intersection point are determined from the image.
  • the shape of the weld comprising the weld bead and the melted portions of the jointed plates is determined from the image by contrast comparison of a plurality of points on each side of the contour of the weld. Points representing the contour line are determined by its position in relation to a known point. Thus such a position is denoted by its distance and orientation from the intersection point or by its cartesian coordinates.
  • the determined shape of the weld is compared with a template of a predeter- mined shape of a wanted weld.
  • the determined weld bead is superimposed by the template.
  • the weld quality is then evaluated by calculating the areas of mismatch between the shapes of the weld and the template. If the template shape is the greater than the weld it would indicate a lack of penetration. If the weld shape is the greater it would indicate an excess of weld material, or excessive penetration.
  • an evaluation system comprising a camera and an evaluation unit including a processor and memory means for storing images and a computer program.
  • the camera may be of the video type and configured to acquire a set of image data representing an image of the weld.
  • the picture is transferred into the memory means by the processor.
  • the computer program is embodied on a computer-readable medium and is configured to control the system in performing the quality evaluation method.
  • the system as controlled by the computer program receive the image data, identify the jointed plates data and the weld data from the image data, compare the weld data with a preferred template data by superimposing the weld data by the template, calculate along the template contour line the contour mismatch between the template and the weld, and by a scoring system evaluate the quality of the weld.
  • a weld is normally described by the length of its two legs from the intersection point
  • the system may comprise optical filtering means. Filtering effects may also be accomplished by image processing means performed by the processor.
  • the shape of the weld is determined by a plurality of points around the weld shape. Firstly the root and the end positions of the legs are determined. Then the throat is determined by length and inclination from the root of points from each of a plurality of equally spread angles between the legs. Then the penetration of the weld along the first jointed plate is determined from positions along spaced apart lines normal to the first jointed plate. Equally the penetration along the second jointed plate is determined from spaced apart lines normal to the second jointed plate. In a preferred embodiment the determination of the weld is defined by the root and the two leg end positions, a plurality of points along the reinforcement, the first jointed plate and along the second jointed plate.
  • the template is an image of an ideal weld image for the present welding operation.
  • a plu- rality of such templates are stored in a memory means in the evaluation unit.
  • the template must be scaled to correctly fit the image of the welded joint. This scaling is made automatically by the evaluation unit. However the scaling and orientation of the template is also made available to the operator.
  • the evaluation of the quality of the performed weld is accomplished by a score system.
  • the areas of overlap and the areas of non-overlap of the template superimposing the weld are calculated by the evaluation unit. These areas are compared and evaluated by a set of rules, which are changeable by the operator. A maximum score will be achieved by the template completely matching the weld. A minimum score will result if there is a com- plete mismatch between the template and the weld.
  • a method of determining a measure of the quality of the arc weld based on a set of image data representing an image of the arc weld in- eludes identifying the image data into a first data set and a second data set, the first data set taken to be weld data and the second data set taken to be background data, and estimating a shape of the arc weld based on the weld data.
  • the image data includes weld data and background data. The estimation provides a measure of the quality of the weld.
  • a computer program for analyzing a set of image data representing an image of a weld includes means for separating the weld data from the background data and means for calculating the surface brightness of the arc weld based on the weld data.
  • the image data includes weld data and background data.
  • the sur- face brightness indicates the quality of the weld.
  • Fig. 1 is a block diagram of a system for analyzing a weld image to determine weld quality according to the invention
  • Fig. 2 is an image of a performed weld of a welded joint where the contour of the weld is determined by a plurality of points,
  • Fig. 3 is an image of a template representing a predetermined weld shape
  • Fig. 4 is an image of a welded joint on which a system of computer related determination techniques is used in order to resolve the contours of the different areas is used.
  • Fig. 5 is a picture of an arc welded joint with definitions of parameters of interest for the quality evaluation
  • a computer based system for evaluating the quality of a weld of a cross section of a welded joint 1 is shown in fig 1.
  • the cross section may either be represented by the natural cross section or by an image, such as a bit map image or a jpeg picture, of the welded joint.
  • the system comprises a camera 2, which may comprise a light source 3 for illuminating the image.
  • the camera may conveniently comprise a video camera such as a DV camera.
  • the camera is connected to a evaluation unit 4 including a processor or computer means.
  • the evaluation unit comprises display means 5 for communication with an opera- tor and memory means 6 for storing templates, images and computer programs.
  • the evaluation unit comprises also a communication link 7 for connection to a communication network including printer means, data bases and such.
  • the weld profile is represented by 26 points as shown in fig 2.
  • the image shows a first jointed plate 8, in the lower part of the fig, and a second jointed plate 9, directing upwardly in the fig, represented by a gray color.
  • the image shows a weld 10 comprising the weld bead and its melted portions into the jointed plates represented by a white color.
  • the image shows the background portion 11 in black color.
  • the weld root 12 must be determined as the intersection point between the two jointed plates.
  • a first leg 13 is denoted from the root to the left most point 14 of the weld.
  • a second leg 15 is denoted from the root along the second jointed plate to the up most point 16 of the weld in the fig.
  • the reinforcement of the weld is defined by points on lines at 0, 15, 30, 45, 60, 75, and 90 degrees from the root between the two jointed plates.
  • the melted portion of the first jointed plate is defined by eight points on perpendicular lines 17, of which six is equally spaced apart along the first leg.
  • the melted portion of the second jointed plate is defined by eight points on perpendicular lines 18 equally spaced apart along the second leg.
  • Video camera 2 is configured to acquire a digital image of weld 1.
  • the digital image including image data comprising weld data, jointed plates data and background data.
  • a method of identifying the image data into a first data set, and a second data set will be described herein below, wherein the first data set is taken to be weld data and the second data set is taken to be jointed plates data.
  • Video camera 2 may be any type of video or im- age capturing device, such as, a digital camera or digital video camera. In this exemplary embodiment, a digital black and white video camera is used. Alternatively, a color digital video camera may be used.
  • the acquired digital image represents the weld 10 and portions of the first jointed plate 8 and the second jointed plate 9.
  • the image also contains informa- tion of the background data 11.
  • a light source 3 such as a light bulb, image processing light, or other light source is provided in the vicinity of weld 1 to provide light in addition to the ambient light to the image or the cross section of the welded joint, so that a better image may be acquired by the video camera.
  • the video camera is configured to provide a digital image file or digital image data to the computer means in the evaluation unit for further processing.
  • the computer means comprises any type of processor or signal processing device, such as, a microprocessor, a micro controller, a laptop computer, a personal computer, a personal digital assistant, etc.
  • the evaluation unit includes the necessary memory, such as random access memory, readonly memory, programmable read-only memory, a hard drive, a floppy disk, some combination thereof, etc., for storing a software program suitable for operating the weld analysis steps.
  • the memory means is also suitable for storing data, such as, the digital image file or digital image data received from the video camera.
  • the computer further includes in- put/output means needed to communicate with the display and user input device.
  • the display may be any type of display for displaying digital image data, charts, text and other data to a human operator, and may be a cathode ray tube (CRT), a liquid crystal display (LCD), a touch-pad interface, etc.
  • the user input device may be a keyboard, a mouse, or other user input device.
  • the computer is configured to process image data received from video camera and provide results via display or by saving the results to memory.
  • the video camera is configured to provide the digital image data via a network to computer for further processing.
  • the network may be any type of communication medium, such as, a local area network (LAN), a wide area network (WAN), an internet protocol network, such as an intranet, the Internet, etc., or other networks.
  • the video camera may be configured with a network card suitable for communicating over the network to the computer.
  • the video camera may provide digital image data to a local computer, the local computer being configured with a network interface means suitable for communicating via the network with the computer in the evaluation unit.
  • some or all of the processing steps may be performed on the local computer, with the remaining steps being performed by the computer in the evaluation unit.
  • a template 12 representing a predetermined image shape of a desired weld is shown in fig 3.
  • a plurality of such templates are stored in the memory means of the evaluation unit. Each template is scaleable by the operator to fit the weld of penetration.
  • An image of a weld to be examined for quality evaluation is shown in fig4.
  • the image shows the principle of defining cross lines for the contour determination.
  • the image also the core of the weld A as an equally legged triangle inscribed in the weld.
  • the method of quality evaluation is a score system. Firstly the image of evaluation is compared with the template of a predetermined weld image. If the image match the template completely there is a maximum score. If there is not a complete match there are a plurality of other parameters that have to come into consideration. In fig 5 a main part of these parameters are defined.
  • the core A of the weld area has two equal legs and a throat size a. Along the first plate there is a first melted portion length zl and along the second plate there is second a melted portion length z2. Between the two plates there is a gap h4. There is a first side penetration hi into the first plate and a second side penetration h2 into the second plate. Between the plates there is a penetration depth h3.
  • the weld reinforcement is denoted by its height bl and width b2. All these parameters are defined by the evaluating system controlled by the computer program and are involved in the scoring sys- tem for determine the quality score of the weld to be examined

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Computer Vision & Pattern Recognition (AREA)
  • General Physics & Mathematics (AREA)
  • Theoretical Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Geometry (AREA)
  • Signal Processing (AREA)
  • Health & Medical Sciences (AREA)
  • Quality & Reliability (AREA)
  • Chemical & Material Sciences (AREA)
  • Analytical Chemistry (AREA)
  • Biochemistry (AREA)
  • Mechanical Engineering (AREA)
  • Immunology (AREA)
  • Pathology (AREA)
  • Length Measuring Devices By Optical Means (AREA)
  • Investigating Or Analyzing Materials By The Use Of Ultrasonic Waves (AREA)
  • Investigating And Analyzing Materials By Characteristic Methods (AREA)
  • Investigating Materials By The Use Of Optical Means Adapted For Particular Applications (AREA)
  • Image Analysis (AREA)

Abstract

L'invention concerne un procédé et un système pour l'évaluation de la qualité d'une soudure à partir d'une image de section transversale de joint soudé (1). Le système comprend une unité d'évaluation (4) qui comporte un processeur pour la mise en oeuvre d'une instruction à partir d'un programme informatique et une mémoire (6) pour l'enregistrement d'images et de programmes informatiques.
PCT/SE2004/000870 2003-06-06 2004-06-04 Evaluation de qualite de soudure Ceased WO2004109268A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
SE0301674-8 2003-06-06
SE0301674A SE526624C2 (sv) 2003-06-06 2003-06-06 Värdering av svetskvalitet

Publications (1)

Publication Number Publication Date
WO2004109268A1 true WO2004109268A1 (fr) 2004-12-16

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PCT/SE2004/000870 Ceased WO2004109268A1 (fr) 2003-06-06 2004-06-04 Evaluation de qualite de soudure

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WO (1) WO2004109268A1 (fr)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2012025679A1 (fr) * 2010-08-25 2012-03-01 Peugeot Citroën Automobiles SA Masque de controle de cordons de soudure
JP2012234255A (ja) * 2011-04-28 2012-11-29 Suzuki Motor Corp 画像処理装置及び画像処理方法
JP2019135545A (ja) * 2013-03-11 2019-08-15 リンカーン グローバル，インコーポレイテッド 仮想現実環境で拡張された教育及びトレーニングを提供するシステム及び方法
CN112419261A (zh) * 2020-11-19 2021-02-26 江汉大学 具有异常点去除功能的视觉采集方法及装置
CN112489010A (zh) * 2020-11-27 2021-03-12 桂林电子科技大学 一种焊缝快速识别方法、装置及存储介质
CN113538325A (zh) * 2020-04-21 2021-10-22 通用汽车环球科技运作有限责任公司 评估点焊完整性的系统和方法
CN114523203A (zh) * 2022-03-13 2022-05-24 扬州沃盛车业制造有限公司 一种激光智能焊接方法及系统
CN115456982A (zh) * 2022-09-05 2022-12-09 武汉理工大学 焊缝熔透性判定方法、装置、电子设备以及存储介质

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0532257A2 (fr) * 1991-09-11 1993-03-17 Toyota Jidosha Kabushiki Kaisha Appareil pour déterminer la qualité de cordon de soudure
DE19807182A1 (de) * 1998-02-20 1999-08-26 Bayerische Motoren Werke Ag Verfahren zur Qualitätsprüfung von Schweißstellen

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0532257A2 (fr) * 1991-09-11 1993-03-17 Toyota Jidosha Kabushiki Kaisha Appareil pour déterminer la qualité de cordon de soudure
DE19807182A1 (de) * 1998-02-20 1999-08-26 Bayerische Motoren Werke Ag Verfahren zur Qualitätsprüfung von Schweißstellen

Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
LAGGOUNE H. ET AL.: "Dimensional analysis of the welding zone", 22ND INT. CONF. INFORMATION TECHNOLOGY INTERFACES ITI, 2000, CROATIA *
MITERAN J. ET AL.: "Characterization of welded area by learning and image processing", IEEE, 1994, ITALY *

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2012025679A1 (fr) * 2010-08-25 2012-03-01 Peugeot Citroën Automobiles SA Masque de controle de cordons de soudure
FR2964051A1 (fr) * 2010-08-25 2012-03-02 Peugeot Citroen Automobiles Sa Masque de controle de cordons de soudure
JP2012234255A (ja) * 2011-04-28 2012-11-29 Suzuki Motor Corp 画像処理装置及び画像処理方法
DE102012207045B4 (de) 2011-04-28 2021-12-23 Suzuki Motor Corporation Bildverarbeitungsvorrichtung und Bildverarbeitungsverfahren
JP2019135545A (ja) * 2013-03-11 2019-08-15 リンカーン グローバル，インコーポレイテッド 仮想現実環境で拡張された教育及びトレーニングを提供するシステム及び方法
CN113538325A (zh) * 2020-04-21 2021-10-22 通用汽车环球科技运作有限责任公司 评估点焊完整性的系统和方法
CN113538325B (zh) * 2020-04-21 2023-09-15 通用汽车环球科技运作有限责任公司 评估点焊完整性的系统和方法
CN112419261A (zh) * 2020-11-19 2021-02-26 江汉大学 具有异常点去除功能的视觉采集方法及装置
CN112489010A (zh) * 2020-11-27 2021-03-12 桂林电子科技大学 一种焊缝快速识别方法、装置及存储介质
CN114523203A (zh) * 2022-03-13 2022-05-24 扬州沃盛车业制造有限公司 一种激光智能焊接方法及系统
CN114523203B (zh) * 2022-03-13 2022-11-29 扬州沃盛车业制造有限公司 一种激光智能焊接方法及系统
CN115456982A (zh) * 2022-09-05 2022-12-09 武汉理工大学 焊缝熔透性判定方法、装置、电子设备以及存储介质

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Publication number Publication date
SE0301674D0 (sv) 2003-06-06
SE526624C2 (sv) 2005-10-18
SE0301674L (sv) 2004-12-07

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