Internal surface condition of mould will affect the metalworking product quality after the casting process. Traditional visual inspection devices cannot keep working when the temperature is beyond 70°C. A vision inspection system protected by a cooling housing was introduced in this paper. The system was designed to provide quality images for defect inspection needs while enduring high temperatures. Illumination strategy consisting of lighting position and orientation was developed to cover 360° inner surface and accentuate defects in images. The housing protected vision system would be motorized into the mould to user-specified position and capture images with trigger mode. Developed algorithm would process images and output inspection results in the backend. Overall inspection of 2-meter mould could be completed within 100 seconds. The developed vision system is fast and low-cost, which can be easily implemented on site and provide defect inspection for cast mould with high temperature.
A novel position measurement system, the so-called image grating system, is presented in this research paper. It features an adjustable measurement range, flexible standoff distance and in-line measurement capabilities. The developed position measurement system includes an image grating attached to the moving stage as the target feature and a line scan camera as the stationary displacement reader. By observing the position of the target feature in the image and applying subpixel image registration, the position of the moving stage can be determined. In order to improve the measurement efficiency, the computations for pattern correlation and subpixel registration are performed in the frequency domain. Calibration and error correction methods are also developed to compensate for the measurement error caused by optical distortion. Experimental data confirms the capability of the image grating technology of ±0.2 μm measurement accuracy within 25 mm measurement range. By applying different optics, the standoff distance and the measurement range can be customized for different precision measurement applications.
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