Automated inspection of foreign objects, cracks and other surface anomalies

Abstract

Automated inspection of foreign objects, cracks, and other surface anomalies. A method for real-time surface flaw detection of additively manufactured and 3D printed parts is provided. The method includes: using one or more illumination sources to direct first light radiation, wherein the first light radiation illuminates a target area of a part being manufactured with a uniform colored light such that the target area appears to have a substantially uniform single color; using one or more feedback cameras to capture a current image of second light radiation scattered or reflected by the target area; and analyzing the current image of the second light radiation using at least one of the one or more feedback cameras by comparing the current image to a previously acquired image to determine whether a surface flaw is present.

Claims

1. A method for real-time surface inspection of additive manufacturing and 3D printed parts, the method comprising the following steps: One or more light sources are used to guide a first light radiation, wherein the first light radiation illuminates a target area of ​​the part being manufactured with uniform colored light for the real-time surface inspection, such that the target area appears to have a substantially uniform monochromatic color that matches the background area of ​​the target area of ​​the part being manufactured. Use one or more feedback cameras to capture a current image of the second light radiation scattered or reflected by the target area; The current image is analyzed using at least one of the one or more feedback cameras by comparing it with a previously acquired image to determine the presence of surface defects; and Adjust at least one of the one or more lighting sources to generate a third light radiation so that the fourth light radiation reflected from the target area is uniform, in addition to the fifth light radiation reflected from the surface defects.

2. The method according to claim 1, further comprising: The additive manufacturing process is stopped based on the determination that the surface defects exist.

3. The method according to claim 1, further comprising: The additive manufacturing process continues based on the determination that no surface defects are present.

4. The method according to claim 1, further comprising: One or more filters are used to modulate the first light radiation to generate modulated first light radiation that results in the uniform colored light.

5. The method according to claim 1, wherein, The first lighting source among the one or more lighting sources includes multiple light-emitting diodes, multiple organic light-emitting diodes, or multiple lasers.

6. The method according to claim 5, wherein, Each element of the plurality of light-emitting diodes or the plurality of organic light-emitting diodes is individually controlled to generate the hue, saturation or color of each element.

7. The method according to claim 1, further comprising: Data obtained from at least one of the feedback cameras will be displayed on a monitor for operator inspection.

8. The method according to claim 1, wherein, The surface defects are detected by analyzing the hue and saturation of the second light radiation to distinguish anomalies.

9. The method according to claim 1, wherein, The step of analyzing the current image using at least one of the one or more feedback cameras further includes: determining a predetermined threshold level that satisfies at least one characteristic of the second light radiation.

10. The method according to claim 9, wherein, The at least one characteristic is hue, saturation, or brightness.

11. The method according to claim 1, wherein, The target area includes the entire part.

12. The method according to claim 1, wherein, The first light radiation is monochromatic illumination radiation.

13. A non-transitory computer-readable medium comprising instructions that, when executed by a hardware processor, cause the hardware processor to perform operations to perform a method for real-time surface inspection of additive manufacturing and 3D printed parts, the method comprising the steps of: One or more light sources are used to control a first light radiation, wherein the first light radiation illuminates a target area of ​​the part being manufactured with uniform colored light for the real-time surface inspection, such that the target area appears to have a substantially uniform monochromatic color that matches the background area of ​​the target area of ​​the part being manufactured. Use one or more feedback cameras to capture a current image of the second light radiation scattered or reflected by the target area to generate a first output; The current image is analyzed using at least one of the one or more feedback cameras by comparing it with a previously acquired image to determine the presence of surface defects; and Adjust at least one of the one or more lighting sources to generate a third light radiation so that the fourth light radiation reflected from the target area is uniform, in addition to the fifth light radiation reflected from the surface defects.

14. The non-transitory computer-readable medium according to claim 13, wherein, The operation also includes stopping the additive manufacturing process based on the determination that the surface defects exist.

15. The non-transitory computer-readable medium according to claim 13, wherein, The operation further includes: continuing the additive manufacturing process based on the determination that the surface defects do not exist.

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