JP7099067B2 - Inspection equipment - Google Patents

Description

The present invention relates to an inspection device.

Conventionally, an inspection device for inspecting a weld bead of a welded structure is known (see, for example, Patent Document 1). In this welded structure, the first plate material and the second plate material having a curved surface shape are welded by laminating fillet welding.

In the inspection device of Patent Document 1, first, measurement shape data for the surface including the weld bead of the welded structure is input. The measured shape data is a measurement result in which the surface shape of the welded structure is measured by using a so-called optical cutting method. The inspection device stores the first plate material shape master data, which is the design surface shape of the first plate material, and the second plate material shape master data, which is the design surface shape of the second plate material. In the inspection device, the first plate material shape master data and the second plate material shape master data are fitted to the measured shape data, and the comparative shape data is created using the fitted first plate material shape master data and the second plate material shape master data. Will be done. The inspection device is configured to inspect the weld bead of the welded structure based on the measured shape data and the comparative shape data.

Japanese Unexamined Patent Publication No. 2010-256326

Here, the fitting of the first plate material shape master data and the second plate material shape master data to the measured shape data is performed at a portion where deformation due to welding of the first plate material and the second plate material does not occur. Then, for example, when the curved surface shapes of the first plate material and the second plate material are formed by press forming, the shapes of the first plate material and the second plate material also change as the mold changes over time, so comparative shape data is created. It becomes difficult to inspect the weld bead. That is, it is necessary to recreate the first plate material shape master data and the second plate material shape master data according to the change in the shapes of the first plate material and the second plate material, and the first plate material shape master data and the second plate material shape master data. It is possible that the inspection efficiency will decrease because the inspection cannot be performed until the product is remade.

The present invention has been made to solve the above problems, and an object of the present invention is to provide an inspection device capable of suppressing a decrease in inspection efficiency.

The inspection device according to the present invention inspects the weld bead of the welded structure to which the first plate material and the second plate material are welded, and includes a storage unit for storing the joint center model and a surface including the weld bead of the welded structure. A surface shape calculation unit that calculates the surface shape including the weld bead of the welded structure based on the image pickup result, and a bead edge detection unit that detects the edge of the weld bead in the surface shape based on the brightness information of the image pickup result. Based on the joint center model and the edge, the standard shape creation part that creates the standard shape corresponding to the surface shape of the first plate material and the second plate material before welding is compared with the surface shape and the standard shape, and the welded structure. It is equipped with an inspection unit that inspects the weld beads of objects. The joint center model is a model of the joint center of the first plate material and the second plate material before welding. The center of the joint is the welding position, and the dimensions are controlled with high accuracy, making it difficult to change.

With this configuration, the reference shape is created using the joint center model that models the joint center that is difficult to change, and it is less likely that the joint center model needs to be recreated, thus suppressing the deterioration of inspection efficiency. can do.
In the above inspection device, based on the portion of the welded structure where the weld bead is not formed, the joint center position detection unit that detects the position of the joint center in the surface shape and the joint center detected by the joint center position detection unit Based on this, the surface shape is provided with a fitting part that fits the joint center model, and the reference shape creation part is configured to create a reference shape based on the joint center model and the edge fitted by the fitting part. You may.

According to the inspection device of the present invention, it is possible to suppress a decrease in inspection efficiency.

It is a schematic block diagram for demonstrating the inspection system by this Embodiment. It is a block diagram which showed the inspection system of FIG. It is a perspective view which showed the lower plate and the upper plate before welding. It is a flowchart for demonstrating the operation example at the time of inspection of the inspection system of FIG. It is a perspective view which shows an example of the surface shape calculated by the PC of the inspection system of FIG. 1 schematically. It is sectional drawing which cut | cut the surface shape of FIG. 5 by line AA.

Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

First, the inspection system 100 including the PC2 according to the embodiment of the present invention will be described with reference to FIGS. 1 to 3.

The inspection system 100 is configured to inspect the weld beads 153 of the welded structure 150, as shown in FIG. In the welded structure 150, the lower plate 151 and the upper plate 152 are welded by, for example, lap fillet arc welding, and the weld bead 153 is formed so as to extend in the Y direction. The weld bead 153 has an edge 153a which is a boundary with the base metal. The lower plate 151 and the upper plate 152 are examples of the "first plate material" and the "second plate material" of the present invention, respectively.

The inspection system 100 is configured to calculate the shape of the surface 150a of the welded structure 150 by a so-called optical cutting method and inspect the weld bead 153 using the result. The inspection system 100 includes an optical head 1 and a personal computer (hereinafter referred to as "PC") 2. PC2 is an example of the "inspection device" of the present invention.

The optical head 1 is provided at the tip of an arm (not shown), for example, and is configured to be movable with respect to the welded structure 150. The optical head 1 includes an exit unit 11 that emits a line laser beam L and an image pickup unit 12 that captures an image of a region irradiated with the line laser beam L of the welded structure 150. For example, the optical head 1 is arranged above the welded structure 150, and is arranged so that the line length direction of the line laser beam L faces the X direction (the direction orthogonal to the extending direction of the weld bead 153) and Y. It is designed to be moved in the direction (the direction in which the weld bead 153 extends).

The PC 2 is configured to be connected to an optical head 1 and control the optical head 1. Further, the PC2 calculates the surface shape 50 (see FIG. 5) of the surface 150a including the weld bead 153 of the welded structure 150, and makes the surface shapes of the lower plate 151B and the upper plate 152B (see FIG. 3) before welding. A corresponding reference shape 70 for comparison (see FIG. 6) is created and configured to inspect the weld bead 153 using its surface shape 50 and reference shape 70.

The surface shape 50 of the surface 150a is calculated based on the image pickup result of the surface 150a including the weld bead 153 of the welded structure 150. The reference shape 70 is created using the joint center model 60 (see FIG. 5). The joint center model 60 is a model of the joint center C (see FIG. 3) of the lower plate 151B and the upper plate 152B before welding, and is master data calculated in advance from the joint center C. For example, the joint center model 60 corresponds to the end face shape of the upper plate 152B before welding. The joint center C is a welding position, and the dimensions are controlled with high accuracy, and it is difficult to change.

As shown in FIG. 2, the PC 2 includes a CPU 2a, a ROM 2b, a RAM 2c, a backup RAM 2d, and an input / output interface 2e. The CPU 2a executes arithmetic processing based on various control programs, maps, and the like stored in the ROM 2b. The ROM 2b stores various control programs and maps referred to when the various control programs are executed. The joint center model 60 is stored in the ROM 2b. The RAM 2c is a memory that temporarily stores the calculation result and the like by the CPU 2a. The backup RAM 2d is a non-volatile memory that stores data and the like to be saved when the PC 2 is turned off. An optical head 1 is connected to the input / output interface 2e, and an image pickup result by the image pickup unit 12 is input. The ROM 2b is an example of the "storage unit" of the present invention.

-Example of operation during inspection of inspection system-
Next, an operation example at the time of inspection of the inspection system 100 according to the present embodiment will be described with reference to FIGS. 1 to 6. The following steps are executed by PC2.

First, in step S1 of FIG. 4, the surface shape 50 (see FIG. 5) of the surface 150a including the weld bead 153 of the welded structure 150 is calculated based on the image pickup result by the image pickup unit 12. The optical head 1 takes an image while moving in the Y direction by a predetermined distance, and the image pickup result is output to the PC 2. In the PC2, the surface shape 50 is calculated and the luminance information of the surface shape 50 is calculated by performing image processing on the input imaging result.

Specifically, the emission line appearing on the surface 150a of the welded structure 150 is imaged by the imaging unit 12 by irradiation with the line laser beam L, and the height of the surface 150a is calculated from the position of the emission line in the emission line image which is the imaging result. To. That is, the position information (two-dimensional data) of the XZ coordinates of the portion of the surface 150a irradiated with the line laser beam L is calculated. This position information has a predetermined measurement interval set in the X-axis direction, and is composed of a set of values on the Z-axis of each measurement point. Further, the luminance of the emission line is also calculated, and the luminance of each measurement point in the X-axis direction is calculated.

Next, as shown by the white arrow in FIG. 1, the optical head 1 is moved by a predetermined distance from one end portion in the longitudinal direction of the welded structure 150 toward the other end portion. Then, the position information (two-dimensional data) of the XZ coordinates of the portion of the surface 150a irradiated with the line laser beam L is calculated, and the brightness of each measurement point in the X-axis direction is calculated. By repeating this, the surface shape (three-dimensional data) 50 of the surface 150a is calculated, and the luminance information of the surface shape 50 is calculated. That is, the surface shape (three-dimensional data) 50 is composed of a set of position information (two-dimensional data) of the XZ coordinates at each measurement point for each predetermined distance in the Y-axis direction. The luminance information is composed of the luminance calculated at each measurement point of the surface shape 50.

Next, in step S2, the position of the center of the joint in the surface shape 50 is detected. Here, in the welded structure 150, as shown in FIG. 1, portions where the weld bead 153 is not formed are left at both ends in the longitudinal direction (Y direction). That is, the end faces 152a of the upper plate 152 that have not been deformed by welding are present at both ends of the welded structure 150 in the longitudinal direction. Therefore, the surface 51 (see FIG. 5) of the surface shape 50 corresponding to the end surface 152a of the upper plate 152 of the welded structure 150 is detected as the position of the center of the joint.

Next, in step S3, the edge 53 (see FIG. 5) of the weld bead 52 in the surface shape 50 is detected based on the luminance information. Since the brightness of the edge 53 changes at the boundary between the weld bead 52 and the base metal, the detection is performed based on the change in the brightness.

Next, in step S4, the joint center model 60 is fitted to the surface shape 50. Specifically, as shown in FIG. 5, the position of the joint center model 60 is moved so that both ends of the joint center model 60 in the longitudinal direction (Y direction) coincide with the surface 51 of the surface shape 50. This makes it possible to obtain the joint center in the weld bead 52.

Next, in step S5, the reference shape 70 is created based on the joint center model 60 and the edge 53. Specifically, as shown in FIG. 6, the line 71 connecting the upper end position 60a of the joint center model 60 and the upper portion 53a of the edge 53 is calculated, and the lower end position 60b and the edge 53 of the joint center model 60 are calculated. A line 72 connecting the lower portion 53b is calculated. Lines 71 and 72 are calculated at each measurement point in the Y-axis direction. The created reference shape 70 is composed of a joint center model 60 and lines 71 and 72, and is a virtual shape corresponding to the surface shapes of the lower plate 151B and the upper plate 152B (see FIG. 3) before welding.

Next, in step S6, the weld bead 153 is inspected based on the surface shape 50 and the reference shape 70. The inspection of the weld bead 153 is performed using a known method. For example, if the surface shape 50 of the region corresponding to the line 72 is less than the line 72, it is detected as an undercut. Further, a root point is set at a position moved downward by the thickness of the upper plate 152 from the upper portion 53a of the edge 53, and the shortest distance from the root point to the surface shape 50 is calculated as the throat thickness.

The "surface shape calculation unit" of the present invention is realized by executing step S1 by the PC2. By executing step S2 by PC2, the "joint center position detection unit" of the present invention is realized. By executing step S3 by PC2, the "bead edge detection unit" of the present invention is realized. The "fitting unit" of the present invention is realized by executing step S4 by the PC2. By executing step S5 by PC2, the "reference shape creating unit" of the present invention is realized. By executing step S6 by PC2, the "inspection unit" of the present invention is realized.

-effect-
In the present embodiment, as described above, by creating the reference shape 70 using the joint center model 60, the reference shape 70 is created using the joint center model 60 that models the joint center C that is difficult to change. As a result, it is less likely that the joint center model 60 needs to be remade, so that a decrease in inspection efficiency can be suppressed. That is, the inspection can be continuously performed as compared with the conventional inspection device that creates the comparative shape data using the first plate material shape master data and the second plate material shape master data.

Further, in the present embodiment, the reference shape 70 can be created by detecting the edge 53 of the weld bead 52 and connecting the edge 53 and the joint center model 60. Further, the edge 53 of the weld bead 52 in the surface shape 50 can be detected based on the luminance information.

-Other embodiments-
It should be noted that the embodiments disclosed this time are examples in all respects and do not serve as a basis for a limited interpretation. Therefore, the technical scope of the present invention is not construed solely by the embodiments described above, but is defined based on the description of the scope of claims. In addition, the technical scope of the present invention includes all modifications within the meaning and scope equivalent to the scope of claims.

For example, in the above embodiment, the example in which the lower plate 151 and the upper plate 152 are flat plates is shown, but the present invention is not limited to this, and the lower plate and the upper plate may have a curved surface shape.

Further, in the above embodiment, an example in which image pickup by the optical head 1 and image processing by the PC 2 are alternately performed is shown, but the present invention is not limited to this, and the images are collectively performed on the PC after all the images taken by the optical head are completed. Image processing may be performed.

Further, in the above embodiment, the example in which the optical head 1 is controlled by the PC 2 is shown, but the present invention is not limited to this, and the optical head may be controlled by another controller.

Further, in the above embodiment, the example in which the optical head 1 is moved with respect to the welded structure 150 is shown, but the present invention is not limited to this, and the welded structure may be moved with respect to the optical head.

Further, in the above embodiment, the example in which the joint center model 60 has the end face shape of the upper plate 152B before welding is shown, but the present invention is not limited to this, and the joint center model is the upper end and the lower end of the end face of the upper plate before welding. It may be composed of two lines of a part.

Further, in the above embodiment, the example in which the welded structure 150 is welded by lap fillet welding is shown, but the present invention is not limited to this, and the welded structure may be welded by T-shaped fillet welding. That is, the inspection target by the inspection device may be a weld bead of a welded structure welded by T-shaped fillet welding. In this case, the joint center model is, for example, a single line where the welded surfaces of the lower and upper plates before welding intersect. That is, the joint center model is, for example, one line at the lower end of the surface of the upper plate on the welded side before welding. In this way, it is possible to create a reference shape based on the edge of the weld bead and the joint center model.

INDUSTRIAL APPLICABILITY The present invention can be used as an inspection device for inspecting a weld bead of a welded structure.

2 PC (inspection device)
2b ROM (storage unit)
50 Surface shape 52 Welded bead 53 Edge 60 Joint center model 70 Standard shape 150 Welded structure 150a Surface 151 Lower plate (first plate material)
152 Upper plate (second plate material)
153 Welded bead

Claims (2)

It is an inspection device that inspects the weld bead of the welded structure to which the first plate material and the second plate material are welded.
A storage unit that stores the joint center model and
A surface shape calculation unit that calculates the surface shape including the weld bead of the weld structure based on the image pickup result of the surface including the weld bead of the weld structure.
A bead edge detection unit that detects the edge of the weld bead in the surface shape based on the luminance information of the imaging result, and the bead edge detection unit.
A reference shape creating unit that creates a reference shape corresponding to the surface shape of the first plate material and the second plate material before welding based on the joint center model and the edge.
An inspection device comprising an inspection unit for inspecting a weld bead of the welded structure by comparing the surface shape with the reference shape. In the inspection device according to claim 1,
A joint center position detection unit that detects the position of the joint center in the surface shape based on the portion of the weld structure in which the weld bead is not formed,
A fitting portion for fitting the joint center model to the surface shape is provided based on the joint center detected by the joint center position detecting portion.
The reference shape creating unit is an inspection device characterized in that it is configured to create the reference shape based on the joint center model fitted by the fitting unit and the edge.

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