Hand held weld scanner ivĦ 1 Introduction This project is a part of a Vinnova founded research project KOST/LOST, where University West is investigating weld quality issues.
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Additional Matlab codes iiiĥ List of symbols CCD camera CMOS Flexcell controller I-P2-P1 Kt-value Leg length MATLAB (Matlab) MIG/MAG welding NDT PTC Throat VCE or Volvo CE Weld face Weld toe WISC Camera based on Charge Coupled Devices technology Complementary Metal Oxide Semiconductor Servo Robot Inc automatic weld measure equipment The weld sample used in all tests in this report A measure of the tension concentration in the weld toe Figure 1 The image shows a fillet weld and explains the leg and throat of the weld The MathWorks software with Image processing toolbox Metal Inert/Active Gas welding Non Destructive Testing Production Technology Centre Figure 1 The image shows a fillet weld and explains the leg and throat of the weld Volvo Construction Equipment The surface of the weld The junction of the base material and the weld face Servo Robot Inc. Trollhättan 22 June 2008 Inger Eriksson iiĤ Contents Summary.i Preface.ii List of symbols.iv 1 Introduction Background Literature survey Purpose and goal Limitations and method Used software Welding standards Weld discontinuities Volvo welding standard Experimentation Image caption with camera and laser line projection Investigation of the scancontrol system Data processing Results Conclusions and further work.20 References.21 Appendices A.
Of course I also want to thank my family, especially my children who, under these years have heard me say this sentence constantly - I just have to do some more studying. And thanks to all schoolmates who among other things have contributed with amusement and surprises. Thanks to Peigang Li for the weld samples, and your interest in my work. I want thank all of you at PTC for help, support and coffee, especially my supervisor and examiner Anna-Karin Christiansson, and supervisor Jari Repo, who always have time to give their opinion and help.
I want to express many thanks to Krister Robles at Sensotest who lent the ScanCONTROL equipment. I have had many supportive people around me and I would like to thank them all. This degree work comprises 15 university points and is the last part of the Mechatronics Engineering program, bachelor level. Author: Examiner: Advisor: Programme: Inger Eriksson Anna-Karin Christiansson Jari Repo University West Mechatronics Engineering, Robotics and Embedded Systems, 120 Credits (180 ECTS) Subject: Mechatronics Level: Basic Date: June Report Number: 2008:MR01 Keywords Fillet weld geometry, image processing, laser line projection, scancontrol Publisher: University West, Department of Engineering Science S Trollhättan, SWEDEN Phone: Fax: Web: iģ Preface This thesis work, performed at Production Technology Centre/University West, has been very interesting, educational and a period with joy of discovery. The equipment is important in order to extract data useful for analysis. It is possible to find the geometry of the weld and it is possible to find defects like spatter, undercut and sharp edges, with laser line projection and camera. The data from the scancontrol system was ready to use and it was quite easy to find different defects and discontinuities in the weld area.
The laser line projection was too short to cover enough of the weld area and it was hard to process the image to find defects in the weld area. Experiments with the first system ended when it was quite obvious that it did not meet the expected result. Matlab was used to process and analyse data from both systems. The first system is an in house built system with a laser line diode and a CMOS camera, the other system is scancontrol, and is a device with integrated camera and laser line. Experiments were performed with two different systems to evaluate their capability to capture the weld geometry. One is hand-held and is applied on the weld afterwards and compares the data with pre set parameters. Some of the articles are about existing devices that can measure welds. This report contains a summary of a literature survey for finding means for optical measurements of weld geometry. If the weld is bigger than necessary the cost and the weight grow, and if the weld is undersized the strength is put at risk. 1 2008:MR01 Methods for automatic inspection of weld geometry Inger Eriksson BACHELOR S THESIS Mechatronics Engineering, Robotics and Embedded Systems Department of Engineering ScienceĢ BACHELOR S THESIS Methods for automatic inspection of weld geometry Summary The earlier in the production chain discontinuities in the weld area are discovered the better and less expensive it is to modify the weld.
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