Fluorescent Penetrant Inspection with Local Camera Shadow Imaging
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Solution Overview
Problem
Existing fluorescent penetrant inspection systems face imaging errors due to the blocking of ultraviolet light by ribs and holes in large-sized cast articles, leading to shadow regions that hinder accurate flaw detection.
Innovation Solution
A fluorescent penetrant inspection apparatus equipped with a wide area camera and a local area camera, where the local area camera captures shadow regions using a second lens barrel with a smaller diameter and longer length than the first, and a robot arm moves the local area camera to image these regions, supplemented by a processor that sets the imaging regions based on design data or actual captured images to minimize errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a wide area camera is used to capture the entire surface of large-sized cast articles, then the inspection coverage is improved, but shadow regions are generated by ribs and holes that block ultraviolet light
Solution Approach 1:
The inspection system is divided into two parts: a wide area camera for overall surface inspection and a local area camera for detailed inspection of shadow regions. This segmentation allows each camera to perform its specialized function optimally without the limitations of a single system trying to do both.
Solution Approach 2:
A robot arm is introduced as an intermediary mechanism to position and move the local area camera to specific shadow regions. This intermediary enables precise targeting of difficult-to-reach areas without requiring the main inspection system to be redesigned for those specific locations.
2Measurement precision
If the local area camera has a longer lens barrel to reach shadow regions, then the ability to capture shadow areas is improved, but the device complexity increases
Solution Approach 1:
The inspection system is divided into two parts: a wide area camera for overall surface inspection and a local area camera for detailed inspection of shadow regions. This segmentation allows each camera to perform its specialized function optimally without the limitations of a single system trying to do both.
Solution Approach 2:
Instead of increasing the lens barrel length in a single dimension, the system uses a robot arm to move the local area camera to different spatial positions and orientations. This multi-dimensional approach solves the shadow region access problem without requiring an excessively long lens barrel.
3Measurement precision
If the imaging region of the local area camera is set based on captured images, then the accuracy is improved, but the inspection time increases
Solution Approach 1:
The processor extracts shadow region information from the wide area camera images in advance, before the local area camera begins inspection. This preliminary identification allows the imaging region to be pre-set, enabling the local area camera to go directly to the correct locations without time-consuming image analysis during the inspection process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The apparatus effectively captures images of shadow regions, reducing imaging errors and allowing for detailed flaw detection within shadowed areas without damaging the camera, thereby enhancing the accuracy of defect identification in large-sized cast articles.
Implementation Method 1
an ultraviolet flaw detection lamp having a ring shape
Implementation Method 2
The second lens barrel supports an objective lens
Implementation Method 3
the fluorescent agent permeates the surface of the test object. Then, the object to be inspected is irradiated with ultraviolet light. At this time, a fluorescence emission image of the test object is captured
Data Source
AI summary
The fluorescent penetrant inspection apparatus comprises a wide area camera and a local area camera. The wide area camera captures an image of an object to be inspected. The wide area camera includes a first lens barrel. The local area camera includes a second lens barrel and a small ring light (an ultraviolet flaw detection lamp). The small ring light is disposed around the second lens barrel. The diameter of the small ring light is less than the diameter of the first lens barrel. And the second lens barrel has a barrel length longer than the first lens barrel.