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Microsoft PowerPoint - Intro - To - Visual Inspection
Microsoft PowerPoint - Intro - To - Visual Inspection
Outline
Introduction Basic principles Manual Vision Inspection
Introduction
-The basic and oldest non-destructive method for detection of surface defects on products, welds, components, and for the assessment of the condition of individual parts of various facilities. -Should always precede other non-destructive method, because it can reveal defects that can prevent correct performance or assessment of results of other non-destructive method. -For the purpose of high quality performance of visual inspection, it is necessary to know the construction of the inspected facility, technology of the production of the inspected product, types of defects and their causes of occurrence. - The quality of visual inspection is based on long-time experiences of the worker who performs this inspection.
Introduction
Can be divided into direct and indirect inspection. Direct visual inspection This inspection can be performed only on places, where the operator can physically get into. The eyesight of the operator is used during this method, respectively simple aids can be used (magnifying glass, gauges, camera etc.). Indirect visual inspection Places that are inaccessible for the eye of the operator are inspected with endoscopes (fixed or flexible).
Introduction
Visual inspection is commonly defined as the examination of a material, component, or product for conditions of nonconformance using light and the eyes, alone or in conjunction with various aids. Visual inspection often also involves, shaking, listening, feeling, and sometimes even smelling the component being inspected. Visual inspection consists of at least two major processes.
The first is a search process. The second is a process of combining relevant knowledge, sensory input, and pertinent logical processes to provide an identification that some anomaly or pattern represents a flaw that poses a risk to the performance of the part.
Visual inspection is commonly employed to support other NDT methods. Digital detectors and computer technology have made it possible to automate some visual inspections. This is known as machine vision inspection.
Introduction
Visual inspection is the most basic and most commonly employed NDT method. It is applicable to a wide variety of material types and product forms. Several characteristics about the part being examined may be determined, which include dimensional conformance, the presence of discontinuities, general fit and wear, and simple cosmetic compliance. It can be performed by direct or indirect methods during various stages of manufacturing or after the component has been placed in-service.
Introduction
The quality of an inspection are affected primarily by four factors. The quality of the detector (eye or camera). The lighting conditions. The capability to process the visual data. The level of training and attention to detail.
Introduction
Basic Principles
The Human Eye
Light enters the eye through the pupil and an image is projected on the retina. Muscles move the eyeball in the orbits and allow you to focus the image on the central retina or fovea.
The retina is a mosaic of two basic types of photoreceptors, rods and cones. Rods are sensitive to blue-green light and are used for vision under dark or dim conditions. Cones operate only in relatively bright light, but they provide us with our sharpest images and enable us to see colors. There are three types of cones
L-cones are red absorbing cones or those that absorb best at the relatively long wavelengths peaking at 565 nm M-cones are green absorbing cones with a peak absorption at 535 nm S-cones are blue absorbing cones with a peak absorption at 440 nm.
c b
180,000 Cones
1 mm
1 mm
Normal visual acuity or 20/20 vision is defined as the ability to resolve a spatial pattern separated by a visual angle of one minute or 1/60 of a degree of arc. One degree of a scene is projected on about 290 micrometers of the retina. In 290 micrometers there are 123 cones and in 1/60 of a degree there 2 cones which is the number required to resolve an object. The size of an object that can be seen at a given distance can be calculated using the following formula: X = (d tan /2)2
When visually inspecting an object for a defect, a comfortable viewing distance d might be around 12 inches. At 12 inches, the normal visual acuity of the human eye is 0.0035 inch. (It must be noted that this value is for the situation where there is good lighting and high contrast
If object visibility was dictated solely by image contrast, the alternating bright and dark bars should appear to have equal height everywhere in the image. However, the bars seem to be taller in the middle of the image.
Inspection of components with fine detail and low contrast may require 100 foot-candles or more. Specification requirements for lighting should be reviewed prior to performing an inspection.
When using machine vision, different but similar performance checks must be performed.
Basic Principles
For best results the inspector or machine vision operator must have:
A basic knowledge of material processing, forming, machining and joining processes. A general understanding of design features, application and service requirements. Specific instructions on what to look for and specific accept/reject criteria.
Inspection Applications
Applications for visual inspection and many and range from looking a product over for obvious defect to performing detailed inspections. Some of the common applications include: Detection of surface anomalies such as scratches, excess surface roughness, and areas void of paint or plating. Crack, porosity, corrosion or other flaw detection. Dimensional conformance. Precision measurements. Foreign object detection. Component location.
Dimensional Conformance
Visual inspection is commonly employed for general dimensional conformance, assembly fit, and alignment between components. Common applications include determining:
Weld size and tolerance. Component dimensions. Material alignment and allowable distortion.
Dimensional Conformance
Welds are commonly inspected for dimensional tolerance. There are several types of gages used to inspect welding fit up and finished weldments. These gages are intended for general inspection where close tolerances are not required. The gage used is determined by the application.
Palmgren gage Fillet gage set V-WACtm gage
Cambridge gage
Dimensional Conformance
Visual inspection is commonly used to determine weld size and tolerances according to standards and engineering specifications.
Throat measurement Leg size determination using a Palmgren gage. with fillet gage.
Dimensional Conformance
Undercut in a weld is readily seen visually. In many cases its depth must be measured to determine if it exceeds code requirements.
Dimensional Conformance
Dimensional Conformance
Component finish dimensions are checked with the use of measurement devices, such as transferring gages and precision measurement gages.
In this image a fabricated girder is being inspected for distortion, sweep and web flatness.
Equipment
Visual inspection equipment includes a variety of different tools. These may range from basic rulers, tape measures and spring type calipers to rigid or flexible borescopes and remote crawlers with cameras. Many tools have been designed for specific applications such as the various weld gauges. Some of the specialized tools such as crawlers have been designed to satisfy the inspection needs in applications where conventional techniques are not feasible.
Optical Aids
Mirrors are valuable aids in visual inspection, they allow the inspection of threaded and bored holes, inside surfaces of pipes and fittings, as well as many others. Magnifiers assist the visual inspector by enlarging the size of the object being examined. Comparators are a magnifier with a measuring capability. The comparator has interchangeable reticles which provide measurements for threads, angles, linear measurement, diameters and radii.
Optical Aids
Borescopes are visual aids used for the inspection of internal surface areas. They are designed for remote viewing in difficult to reach areas such as jet engines, cylinders, tanks, and various enclosed chambers. Borescopes are available in many different diameters and lengths, and are classified as rigid or flexible.
Clean Surface
Corrosion Damage
Optical Aids
Advances in technology has allowed video equipment to be adapted to portable and robotic devices. Portable video probes allow inspectors to remotely perform examinations in closed chambers which are inaccessible by convention inspection means. Robotics have been developed whereby cameras can be affixed to crawlers and submersibles.
Retrieval tools can be affixed to robotics to remove foreign objects.
Conventional recording techniques may be employed for image capture and storage with many of the remote video inspection methods.
Assembly Verification
Glossary of Terms
Borescope: A visual inspection aid used for the inspection of internal surfaces. Borescopes are rigid and flexible. Corrosion: The deterioration of a metal by chemical or electrochemical reaction with its environment. Defect: A discontinuity which interferes with the usefulness of a part. A fault in any material or part which is detrimental to its serviceability.