Scanner of automatic paint inspection
As explained before, the principle is to observe in reflection a known pattern shown on a big tunnel shaped display. This display’s section is adapted to the vehicle overall shape (universal to all vehicles of similar overall sizes). Lengthwise the vehicle is to be measured in 4-6 positions, in accordance with its given length.
Depending on the line configuration, Virelux proposes 2 different scanner configurations:
the first one with an automated display movement to cover the different vehicle positions.
and a second one based upon the vehicle to be moved to the different positions.
The first advantage lays in a very high equipment accuracy, resulting from advanced camera technology combined with the latest deflectometry algorithms.
A second aspect is the robustness of a metrology-based equipment (it is based upon a physical measurand, not on AI interpretation of an image).
It has also a very High repeatability
Fast, allowing very low cycle times
As the vehicle is in stand still configuration, all external influence parameters are limited to a minimum (no risk the speed of scan movement could influence the results negatively).
Also to be considered is the unique setup for positioning the cameras: switching from one body type to another is no problem.
Change over to a new vehicle can be done locally, in a few days
Finally, OptiPaint comes at considerably lower cost than traditional robot based configuration.
Existing defect Library
Currently, OptiPaint detects the following type of defects :
Seeds (cluster, yarn seeds) with a minimum size of 0,5mm
Scratches with a minimum length of 8 mm
Sags with a minimum length of 3 mm
Craters with a minimum diameter of 2 mm
Pinholes with a minimum size of 0,5 mm
Dents with a minimum diameter of 1,5 mm
All of these, with a repreatability of > 94% at smallest defect
Note: These standards can be adapted in accordance with customer specifications.
The system, once the acquisition and processing is done, provides a measurement report with the number of defects by category, and by bodywork element.
The report can then be exported in DDR, CSV and / or pdf format.
Reports containing possible defects are highlighted, and sent automatically to the repair zone.
Low cycle times:
A measurement cycle is composed of:
- Once the vehicle is in position:
Acquisition: with a duration of 32-38 sec, the acquisition records, for all cameras simultaneously, a set of reflection images during one scan.
Note: the vehicle can already be moved immediately after the scan!
- Processing: taking another ~35 seconds (depending number of defect types and min sizes), creates the raw maps, thresholds and filters them, applies the defined masks and runs the detection algorithm in accordance with the preset defect library.
- Report display: Immediately after processing, the report is available to be sent to the repair station.
Note: limit value setting, for each type of defects, is done on the repair station.
OptiPaint System, Argos software pack:
Our OptiPaint systems come equipped with a proprietary inspection software pack: ARGOS.
By default, all important information is displayed on the dashboard: current vehicle with its specification, counters, cameras’ statut….
First level administration allows the user to check and interact with the OptiPaint system such as log message, set a new type of parameters…
Beyond this a higher level of administrator includes functions as for example: maintenance settings, mask generator tools, imaging parameter, archiving functions and defect library thresholds...
In general the process flow of one measurement consists of the following main steps
image acquisition (in 4 to 6 vehicle sections)
image compilation, flattening and fusion
map generation and thresholding
defect classification in accordance with set defect library
Once the acquisition and pre-processing are done, the defects are firstly sorted in accordance to type (scratch – dent - …),
And then sorted for severity (acceptable – unacceptable)