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on-line scanning of extrusion and tires.
by：SAN
2020-03-10
The standards of quality and production control are becoming more and more strict.
Quality control methods often require the removal of materials or finished objects from the production flow.
Additional processing of measuring and recording notes takes time and money.
On-there are several advantagesLine check.
Check the materials during production so that the production process will not be interrupted.
Records are kept electronically to eliminate clerical work and human error (
May have completely eliminated humans).
Solve the tolerance problem quickly, so as to optimize the use of materials and avoid waste.
This article will describe a
Contact measurement on the production line.
How does laser scanning work?
Figure 1 is single-
Point laser scanning geometry.
Note how the video signal changes the position in the sensor as the height of the object being measured changes.
The algorithm provides a single height measurement when reading the sensor.
To calculate two-
Many readings must take the size shape.
The encoder is usually used to provide the second axis that connects these readings. [
Figure 1 illustration omitted]
The line laser measurement method is shown in figure 2.
Exposure of single-line laser snapshots in charge-coupled devices, not many single-point measurements (CCD)camera array.
No need to move the laser/camera components to calculate two-
Size shape. [
Figure 2 illustration omitted]
Figure 3 is an example of a line laser system with three scanners.
Display scan short fax.
Instantly get the complete outline.
No moving parts. [
Figure 3 illustration omitted]
How does the line laser scanner work?
The camera view in Figure 4 shows the brightness of the line laser on the extruded rubber.
The CCD camera is exposed to provide a view window.
Please note that the laser line is completely through the sample.
Using visible laser lines and displaying the camera view provides an operator with a useful diagnosis to understand how the system works.
As one can imagine, adjusting and calibrating is simplified with a list of pictures instead of fuzzy values.
Adjust the exposure time of the CCD camera to optimize the view of the laser line to give the measurement profile.
If the laser line is so bright that it covers several pixels with the largest brightness, the exact position of the laser on the object is lost (Saturated White).
Proprietary software locates the laser line in the camera image and calculates the number of pixels that are too bright or saturated.
The setting parameters in the software allow a certain percentage of saturated pixels.
After taking each photo, adjust the exposure of the camera to maximize the position accuracy of the laser line. [
Figure 4 illustration omitted]
Note that in figure 4 and most computer screen examples, the information header is missing.
This title includes screen status, scanner status, machine status, job status, current measurements for each electronic probe, and commands: archive, calibrate, exit, freeze, graphics, help, laser, parameters, QC, settings and views.
When the laser line is in the camera\'s view, the laser coordinates are converted from the camera view to the X/Y view.
Provide measurement information along the entire laser line that provides the outline of the object.
The high resolution camera has hundreds of pixels and can calculate measurements for each pixel.
However, not all dimensions of an object are interesting.
To focus on key dimensions, the system comes with a different software probe from the calipers.
Each probe can be configured around key dimensions.
We have designed a variety of products including average X and Y size, peak Valley and left and right edges.
These probes are displayed on the graphical X/Y representation of the object.
The design of the software probe is not just to show the size analysis.
Two limits are programmed in the probe.
A warning is provided (
Probe changes from green to yellow)
When the critical size is slightly out of tolerance.
Another offer error (
Probe changed from yellow to red)
When the size is dangerous beyond the tolerance.
Perhaps a more interesting view of the probe over time is provided with a extruded QC chart.
The bottom of Figure 5 shows the operating standard deviation to measure production consistency.
The probe has entered the yellow warning range.
Note how measurement changes are reflected in column S or standard deviation charts.
Each probe has a separate QC chart. [
Figure 5 illustration omitted]
How do you calibrate the line laser scanner?
When the extrusion run is configured satisfactorily, the configuration is saved in the computer file.
This provides a quick turnaround when faced with switching to a different product or running.
In order to adjust the system to materials of different sizes and shapes, the system must be flexibly and quickly recalibrated.
Figure 6 is a graphical view of the calibration fixture.
Please note how to fill the viewing area with a known size using 13 different probes.
After the probe is located in the observation area, the system issues a calibration command.
The parameters tell the software to calibrate the actual dimensions of the fixture and fix the various X and Y coordinates through the calibration algorithm. [
Figure 6 illustration omitted]
Some systems need to maintain accuracy within such a large area of observation that a laser/camera scanner is not enough.
The software has the functions of multiple scanners built into it.
Configuration parameters tell how many scanners are in the system.
The displayed system consists of two scanners.
The yellow line is information from a laser/camera scanner;
The white one is other information.
The software combines two sets of data to provide a continuous measurement profile.
What kind of objects can be measured?
Examples of extrusion products show how the system adapts to each product.
Extrusion molding under a camera with a laser line can capture all points of interest.
Objects with flat or circular edges are ideal for line laser measurement systems.
If there are sharp edges or pockets in the part, the laser line may be lost from the camera\'s perspective.
However, by adjusting a scanner to illuminate the interior of any crack, difficult areas can still be measured.
The system is designed to allow any or all scanners to \"see\" many different angles quickly and flexibly.
Figure 7 and Figure 8 show how the scanner adjusts the exposure time based on the color and reflectivity of the material.
Pay attention to the sharp angle where the laser line disappears.
In order to observe these areas and thus measure them, it is necessary to be able to adjust the angle of the scanner.
Figure 7 is the camera view of off-
White rubber extrusion.
This is in contrast to the black matte of the rubber sample in figure 4.
ProScan adjusts for any color or finish. [Figures 7-
8 illustration omitted]
The exposure time displayed at the top of the home screen is significantly shortened with the exposure time on black rubber.
By automatic exposure, the system can be adjusted according to the color and finish of the material being measured and the variable lighting conditions on the factory floor.
The tire tread is not from Fiat.
Fortunately, the line laser profile does not care if the object under test is flat or round.
A system was specially designed to measure the tire and tire tread.
Multiple scanners will give a bead. to-
Tire rim profile.
How do you measure tires?
For tires, the scan head is just hung above the tire.
Each profile measures the tread profile at the moment of laser emission and camera exposure.
When a snapshot is taken, the profile is calculated and added to an array of previous profiles.
In this way, create a complete 3D image.
If more measurements are needed, the rotation speed of the tire will be slower.
The measurement of the tire scanner can reach 100 profiles/second as needed.
Compile and display data for partial tire scans.
The 3D color coded display combines all the profiles taken when the tire rotates.
A very detailed analysis of the tread is possible.
The ProScan line of the detection device consists of a CCD camera and a line that measures the profile of the cross section to produce a laser.
A single camera and laser pair are called scanners.
In order to cover the field of view and meet the measurement specifications, multiple scanners are aligned.
The computer control of the scanner allows the scanning rate to exceed 100 profiles per second.
When the material passes in front of each scanner, the image is collected and processed by the personal computer.
The image is processed to convert the laser line in the camera space to the profile in the X/Y space.
The computer collects all the outlines and combines the data into a 3D map of the material.
The multiple scanner configurations of ProScan provide the ability to measure a variety of rubber extrusion products.
The use of flexible software measuring probes to monitor key dimensions simplifies intuitive production displays.
To measure the tire, it is easy to adjust the mechanical structure to establish a 3D tire tread measurement system.
Finally, ProScans in the case of little capital investment will help to produce more stringent tolerances, less rejection, shorter installation time, less paperwork, and most importantly increased monetary returns
Quality control methods often require the removal of materials or finished objects from the production flow.
Additional processing of measuring and recording notes takes time and money.
On-there are several advantagesLine check.
Check the materials during production so that the production process will not be interrupted.
Records are kept electronically to eliminate clerical work and human error (
May have completely eliminated humans).
Solve the tolerance problem quickly, so as to optimize the use of materials and avoid waste.
This article will describe a
Contact measurement on the production line.
How does laser scanning work?
Figure 1 is single-
Point laser scanning geometry.
Note how the video signal changes the position in the sensor as the height of the object being measured changes.
The algorithm provides a single height measurement when reading the sensor.
To calculate two-
Many readings must take the size shape.
The encoder is usually used to provide the second axis that connects these readings. [
Figure 1 illustration omitted]
The line laser measurement method is shown in figure 2.
Exposure of single-line laser snapshots in charge-coupled devices, not many single-point measurements (CCD)camera array.
No need to move the laser/camera components to calculate two-
Size shape. [
Figure 2 illustration omitted]
Figure 3 is an example of a line laser system with three scanners.
Display scan short fax.
Instantly get the complete outline.
No moving parts. [
Figure 3 illustration omitted]
How does the line laser scanner work?
The camera view in Figure 4 shows the brightness of the line laser on the extruded rubber.
The CCD camera is exposed to provide a view window.
Please note that the laser line is completely through the sample.
Using visible laser lines and displaying the camera view provides an operator with a useful diagnosis to understand how the system works.
As one can imagine, adjusting and calibrating is simplified with a list of pictures instead of fuzzy values.
Adjust the exposure time of the CCD camera to optimize the view of the laser line to give the measurement profile.
If the laser line is so bright that it covers several pixels with the largest brightness, the exact position of the laser on the object is lost (Saturated White).
Proprietary software locates the laser line in the camera image and calculates the number of pixels that are too bright or saturated.
The setting parameters in the software allow a certain percentage of saturated pixels.
After taking each photo, adjust the exposure of the camera to maximize the position accuracy of the laser line. [
Figure 4 illustration omitted]
Note that in figure 4 and most computer screen examples, the information header is missing.
This title includes screen status, scanner status, machine status, job status, current measurements for each electronic probe, and commands: archive, calibrate, exit, freeze, graphics, help, laser, parameters, QC, settings and views.
When the laser line is in the camera\'s view, the laser coordinates are converted from the camera view to the X/Y view.
Provide measurement information along the entire laser line that provides the outline of the object.
The high resolution camera has hundreds of pixels and can calculate measurements for each pixel.
However, not all dimensions of an object are interesting.
To focus on key dimensions, the system comes with a different software probe from the calipers.
Each probe can be configured around key dimensions.
We have designed a variety of products including average X and Y size, peak Valley and left and right edges.
These probes are displayed on the graphical X/Y representation of the object.
The design of the software probe is not just to show the size analysis.
Two limits are programmed in the probe.
A warning is provided (
Probe changes from green to yellow)
When the critical size is slightly out of tolerance.
Another offer error (
Probe changed from yellow to red)
When the size is dangerous beyond the tolerance.
Perhaps a more interesting view of the probe over time is provided with a extruded QC chart.
The bottom of Figure 5 shows the operating standard deviation to measure production consistency.
The probe has entered the yellow warning range.
Note how measurement changes are reflected in column S or standard deviation charts.
Each probe has a separate QC chart. [
Figure 5 illustration omitted]
How do you calibrate the line laser scanner?
When the extrusion run is configured satisfactorily, the configuration is saved in the computer file.
This provides a quick turnaround when faced with switching to a different product or running.
In order to adjust the system to materials of different sizes and shapes, the system must be flexibly and quickly recalibrated.
Figure 6 is a graphical view of the calibration fixture.
Please note how to fill the viewing area with a known size using 13 different probes.
After the probe is located in the observation area, the system issues a calibration command.
The parameters tell the software to calibrate the actual dimensions of the fixture and fix the various X and Y coordinates through the calibration algorithm. [
Figure 6 illustration omitted]
Some systems need to maintain accuracy within such a large area of observation that a laser/camera scanner is not enough.
The software has the functions of multiple scanners built into it.
Configuration parameters tell how many scanners are in the system.
The displayed system consists of two scanners.
The yellow line is information from a laser/camera scanner;
The white one is other information.
The software combines two sets of data to provide a continuous measurement profile.
What kind of objects can be measured?
Examples of extrusion products show how the system adapts to each product.
Extrusion molding under a camera with a laser line can capture all points of interest.
Objects with flat or circular edges are ideal for line laser measurement systems.
If there are sharp edges or pockets in the part, the laser line may be lost from the camera\'s perspective.
However, by adjusting a scanner to illuminate the interior of any crack, difficult areas can still be measured.
The system is designed to allow any or all scanners to \"see\" many different angles quickly and flexibly.
Figure 7 and Figure 8 show how the scanner adjusts the exposure time based on the color and reflectivity of the material.
Pay attention to the sharp angle where the laser line disappears.
In order to observe these areas and thus measure them, it is necessary to be able to adjust the angle of the scanner.
Figure 7 is the camera view of off-
White rubber extrusion.
This is in contrast to the black matte of the rubber sample in figure 4.
ProScan adjusts for any color or finish. [Figures 7-
8 illustration omitted]
The exposure time displayed at the top of the home screen is significantly shortened with the exposure time on black rubber.
By automatic exposure, the system can be adjusted according to the color and finish of the material being measured and the variable lighting conditions on the factory floor.
The tire tread is not from Fiat.
Fortunately, the line laser profile does not care if the object under test is flat or round.
A system was specially designed to measure the tire and tire tread.
Multiple scanners will give a bead. to-
Tire rim profile.
How do you measure tires?
For tires, the scan head is just hung above the tire.
Each profile measures the tread profile at the moment of laser emission and camera exposure.
When a snapshot is taken, the profile is calculated and added to an array of previous profiles.
In this way, create a complete 3D image.
If more measurements are needed, the rotation speed of the tire will be slower.
The measurement of the tire scanner can reach 100 profiles/second as needed.
Compile and display data for partial tire scans.
The 3D color coded display combines all the profiles taken when the tire rotates.
A very detailed analysis of the tread is possible.
The ProScan line of the detection device consists of a CCD camera and a line that measures the profile of the cross section to produce a laser.
A single camera and laser pair are called scanners.
In order to cover the field of view and meet the measurement specifications, multiple scanners are aligned.
The computer control of the scanner allows the scanning rate to exceed 100 profiles per second.
When the material passes in front of each scanner, the image is collected and processed by the personal computer.
The image is processed to convert the laser line in the camera space to the profile in the X/Y space.
The computer collects all the outlines and combines the data into a 3D map of the material.
The multiple scanner configurations of ProScan provide the ability to measure a variety of rubber extrusion products.
The use of flexible software measuring probes to monitor key dimensions simplifies intuitive production displays.
To measure the tire, it is easy to adjust the mechanical structure to establish a 3D tire tread measurement system.
Finally, ProScans in the case of little capital investment will help to produce more stringent tolerances, less rejection, shorter installation time, less paperwork, and most importantly increased monetary returns
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