Automotive

Laser Welding

Welding tailored blanks is one of the most important applications of laser welding in the automotive industry. An automated industrial-suited weld inspection system should enable a 100% control of the laser weld.

By analyzing the profile, the weld structure and pores in a single compact sensor the fully automated online inspection system controls to 100% the weld at laser welding. Especially important are thereby the three-dimensional absolute geometry of the weld profile and the homogeneity of the weld surface.
At image pre-processing the position and edge of the weld must be recognized accurately and fast. The blank part or workpiece material must be differed from the weld area and the data traffic be reduced. To achieve this, information such as brightness, contrast as well as specific geometry and size information are analyzed using special algorithms.
To determine all errors laser triangulation (3D) and grey image analysis (2D) are combined and three parallel procedures are used: 3D profile analysis, 2D weld structure analysis (weld texture analysis) and 2D pore analysis. Due to fewer downtimes the reaction times were reduced, increasing process security.

Project Details

Industry:

Automotive Industry

Featured Application:

Laser Welding of Tailored Blanks

Solution:

Laser triangulation (3D) and grey image analysis (2D) along with three parallel procedures: 3D profile analysis, 2D weld structure analysis (weld texture analysis) and 2D pore analysis.

Identification of Wheel / Rim Types of Cars

Aluminum wheels / rims for cars are manufactured today according to individual specifications. Therefore, it is getting more and more difficult to distinguish them due to small characteristic changes. There exist identical wheels (rims) in matted black and glossy chrome. Modern designs also combine color and brilliance elements with a black base color.

During the single manufacturing steps car wheels / rims are separated several times and mixed again. Before they reach single inspection stations the respective wheel / rim type must therefore be recognized free of doubt by wheel geometry and design comparisons, to convey them to the next process step appropriately resp. to control the next step. Syscon, a German system company for machine vision, reached optimized output images using the software solution VisualApplets and the High Dynamic Range (HDR) application on a programmed Baumer camera within the own solution DesignSweeper, which has been used for more than 20 years in many rim plants.
By HDR five grey scale images are acquired with ascending exposure time and merged to a well-balanced exposed whole image. Image parts that are too bright or dark get discarded (linear weighting), whereas the surface of the rim is represented well-balanced illuminated. Thus, even small logos and symbols can be recognized in the image, irrespective of a matted, glossy, bright or dark rim surface.
VisualApplets with the HDR application has been implemented on the camera FPGA using VisualApplets Embedder. Due to image pre-processing and image processing on the FPGA no CPU resources are necessary for image processing.

Project Details

Industry:

Automotive Industry

Featured Application:

Identification of wheel / rim types of cars

Solution:

HDR application with VisualApplets implemented on the camera FPGA using VisualApplets Embedder