MODULE-V

COMPUTER AIDED QUALITY

CONTROL
• Inspection methods
• Contact inspection methods
• Non contact inspection methods
• Computer aided testing
 QC AND CIM
• A wide range of computer-based instrumentation is being used for quality control.
• In particular the increased sophistication of sensors and transducers, which are part of
CIM, is making it easier to carry out pre-process, in-process, and post-process inspection.
• Inspection and testing are meant to reduce wastage and make maximum use of
resources.
• The incorporation of digital techniques in manufacturing systems and the use of
computers and microprocessors for controlling manufacturing processes have resulted in
the introduction of several types of inspection techniques.
• In modern manufacturing systems, inspection is no longer considered as an appraisal
oriented process (ACCEPTED/REJECTED) but as prevention oriented process. At present,
inspection with the use of computers has acquired a status of its own known as
COMPUTER AIDED INSPECTION (CAI) and is an integral part of Computer Integrated
Manufacturing.
 OBJECTIVES OF CAQC
• The objectives of computer-aided quality control are to:
i. Improve product quality
ii. Increase productivity in the inspection process
iii. Increase productivity
iv. Reduce lead-time
v. Reduce wastage due to scrap/rework
 Contact inspection methods
Coordinate Measuring Machine (CMM)
• The coordinate measuring machine (CMM) is the most prominent example
of the equipment used for contact inspection of parts.
• When used for CIM these machines are controlled by CNC. A typical three-
dimensional measuring machine consists of a table, which holds the part in
a fixed, position, and movable head, which holds a sensing, probe.
• The probe can be moved in three directions corresponding to the X, Y and Z
Coordinates. For manual operation, the control unit is provided with
joysticks, or other devices which drive X, Y and Z servo motors (AC/DC).
• During operation, the probe is brought into contact with the part surface to
be measured and the three co-ordinate positions are indicated to a high
level of accuracy.
 Contact inspection methods
Coordinate Measuring Machine (CMM)
 Contact inspection methods
Coordinate Measuring Machine (CMM)
• The major features of a CMM are:
• (i) Stationary granite measuring table: Granite table provides a stable
reference plane for locating parts to be measured. It is provided with a grid
of threaded holes defining clamping locations and facilitating part
mounting. As the table has a high load carrying capacity and is accessible
from three sides, it can be easily integrated into the material flow system
of CIM.
• (ii) Length measuring system: A 3-axis CMM is provided with digital
incremental length measuring system for each axis.
• (iii) Air bearings: The bridge, cross beam and spindle of the CMM are
supported on air bearings with high rigidity. They are designed insensitive
to vibrations.
 Contact inspection methods
Coordinate Measuring Machine (CMM)
• (iv) Control unit: The control unit allows manual measurement and
self teach programming in addition to CNC operation. The control unit
is microprocessor controlled. Usually a joystick is provided to activate
the drive for manual measurement.
• CNC Measuring Centers are provided with dynamic probe heads and a
probe changing system, which can be operated manually or
automatically.
• (v) Software: The CMM, the computer and the software together
represent one system whose efficiency and cost effectiveness depend
to a large extent on the software
 ADVANTAGES OF CNC OPERATION OF CMM
1. Shorter measuring times
2. Higher throughput rates
3. Better repeatability
4. Economical even for small batches
5. Simple operation
Non contact inspection methods
Machine vision system
 Non contact inspection methods
Machine vision system
• The operation of a machine vision system can be divided into the following
three functions: (1) image acquisition and digitization, (2) image processing
and analysis, and (3) interpretation
1) Image Acquisition and Digitization
• Image acquisition and digitization is accomplished using a digital camera
and a digitizing system to store the image data for subsequent analysis. The
camera is focused on the subject of interest, and an image is obtained by
dividing the viewing area into a matrix of discrete picture elements (called
pixels), in which each element has a value that is proportional to the light
intensity of that portion of the scene. The intensity value for each pixel is
converted into its equivalent digital value by an ADC
 Non contact inspection methods
Machine vision system
2. Image Processing and Analysis
• The second function in the operation of a machine vision system is image processing and
analysis. A number of techniques have been developed for analyzing the image data in a
machine vision system. One category of techniques in image processing and analysis,
called segmentation, is intended to define and separate regions of interest within the
image. Two of the common segmentation techniques are thresholding and edge
detection.
• Thresholding involves the conversion of each pixel intensity level into a binary value,
representing either white or black. This is done by comparing the intensity value of each
pixel with a defined threshold value. If the pixel value is greater than the threshold, it is
given the binary bit value of white, say 1; if less than the defined threshold, then it is
given the bit value of black, say 0.
• Edge detection is concerned with determining the location of boundaries between an
object and its surroundings in an image. This is accomplished by identifying the contrast
in light intensity that exists between adjacent pixels at the borders of the object.
 Non contact inspection methods
Machine vision system
3. Interpretation
• For any given application, the image must be interpreted based on
the extracted features. The interpretation function is usually
concerned with recognizing the object, a task called object
recognition or pattern recognition. The objective in this task is to
identify the object in the image by comparing it with predefined
models or standard values.
• Two commonly used interpretation techniques are template matching
and feature weighting.
Optical Inspection Methods
Laser Systems
 Optical Inspection Methods
Laser Systems
• The unique feature of a laser (laser stands for light amplification by stimulated emission
of radiation) is that it uses a coherent beam of light that can be projected with minimum
diffusion.
• The scanning laser device falls into the latter category. the scanning laser uses a laser
beam that is deflected by a rotating mirror to produce a beam of light that can be
focused to sweep past an object. A photodetector on the far side of the object senses
the light beam except for the time period during the sweep when it is interrupted by the
object. This time period can be measured with great accuracy and related to the size of
the object in the path of the laser beam. The scanning laser Beam device can complete
its measurement in a very short time.
• Hence, the scheme can be applied in high-production on-line/post-process inspection or
gaging. A microprocessor counts the time interruption of the scanning laser beam as it
sweeps past the object, makes the conversion from time to a linear dimension, and
signals other equipment to make adjustments in the manufacturing process and/or
activate a sortation device on the production line. Applications of the scanning laser
technique include rolling mill operations, wire extrusion, and machining and grinding
processes
 Computer-aided testing
• Computer-aided testing is simply the application of the computer in the testing procedure. There are different levels of
automation which can be found in CAT. At the lowest level, the computer would be used simply to monitor the test and analyze the
results, but the testing procedure itself is manually set up, initiated, and controlled by a human operator.
• In this case the computer receives the data from a data logger or a data acquisition system and prepares a report of the test
results.
• At a much higher level of automation are computer-integrated test cells, which consist of a series of testing stations
interconnected by a materials handling system. An automated test cell has most of the earmarks of a computer-integrated
manufacturing system.
• These cells are often interfaced directly to the assembly line so that the products flow automatically from final assembly to final
testing. All facets of the operation of the test cell are under computer control. The individual stations typically operate
independently of each other.
• During operation, a product is transferred by the handling system to an available test station. The test station automatically
registers the product in the proper location and orientation, and attaches the required connecting apparatus to conduct the test.
The testing then begins with the computer monitoring the data and analyzing the results. If the product passes the test, it is
automatically moved to the next assembly operation or final packing. In the event the product fails to pass the test, there is often
the provision to transfer the product to a manual station for examination by human operator. The computer can often be helpful in
this regard by indicating the reason the test failed, or even diagnosing the problem and recommending the most promising repair
alternative. Another feature Of some test cells is the capability to make adjustment in the product during the test cycle to fine
tune its functional operation .