Dr. Ralf Freiberger. TEMA GmbH / Mühlbauer Group

Transcription

1 Welcome to ADF&PCD Paris 2018

2 Inline Final Inspection of Aerosol Cans Dr. Ralf Freiberger TEMA GmbH / Mühlbauer Group

3 Overview 1. Purpose 2. State of the Art: Integration in Line 3. New: Inspection at End of Line 4. Summary

4 Purpose A can is nowadays more than a simple container! The cans have now become - highly resource-conserving - efficient - almost freely designable objects due to new findings from materials science

5 Purpose Higher throughputs new materials (recycled aluminum) Thinner wall thickness More complex shapes (more inelastic transformations) More critical defects, even smallest defects have to be avoided! Challenge for better defect inspections! Choice of right image processing technology makes it possible for production window of forming process to be used with maximum efficiency in terms of manufacturability!

6 State of the Art: Integration in Line

7 State of the Art: Integration in Line Surface Inspection Print Inspection Can Top Inspection Inspection directly in line saves money, a defective vessel will not pass following processing steps. But: In the following processing steps a new defect can arise, that will not be detected anymore, because it occurs behind the inspection units.

8 State of the Art: Integration in Line Inspection of print directly behind the printer Inspection of curl & shoulder directly in tool plate of necking machine illumination camera PI (Print Inspection) CTI (Can Top Inspection) Patent granted DE

9 State of the Art: Integration in Line Patent granted DE CTI (Can Top Inspection) OK Top view: all information in one image Backside of curl and hidden shoulder is visible! Picture by courtesy of Ball, Velim CZ

10 State of the Art: Integration in Line CTI (Can Top Inspection) Detection of hidden defects One camera system in necker tool-plate with additional optic

11 New: Inspection at End of Line = Print Inspection + Can Top Inspection + Shape Control

12 New: Inspection at End of Line Can Inspection Machine: Can handler Inspection units First presentation of demonstrator at Metpack, Germany, May 2017

13 New: Inspection at End of Line Shape Control Can Inspection Machine Print Inspection Can Top Inspection

14 New: Inspection at End of Line World s fastest new 3D-camera implemented! Shape Control Can Inspection Machine Print Inspection Can Top Inspection 240 / min

15 3D-Measurement (Laser triangulation)

16 Images from laser line are 30 khz and are put together Overexposed for demonstration The thinner the line the better the measurement

17 Sensor Because of Si-based chips detectors have their highest response in red and IR-range. Red laser line produces good response on chip. But line width is too large.

18 2017/08/23 Laser line bpp=m 2 l Gaussian shape, diffraction limited Deep blue has the thinnest line in VIS Also speckles are reduced (diameter speckle prop. to l) (If roughness of the surface is in the range of the wavelength speckles) Fiber-coupled diode laser with 10 µm (width) blue line Straylight can be filtered out by use of bandpass-filter, just the laser-wavelength is transmitted beam parameter product M 2 beam quality factor l wavelength Speckles

19 Blue laser with M Fiber-coupled laser Micro focus line Class 2M ( safe, no housing necessary)

20 Need of thin laser line blue laser (450 nm) Camera has to be more sensitive

21 capabilities/aerosol/1-piece-aluminum-shaped 30 mm khz 16 subpixel levels 3200 height levels 45 mm e.g. 30 mm 45 mm Diameter Max. Resolution = 7.5 mm / 3200 = 2 µm

22 Laser 3D-Camera Overexposed and slow motion for demonstration Can The principle:

23 Laser 3D-Camera Overexposed and slow motion for demonstration Can The principle:

24 Laser 3D-Camera Overexposed and slow motion for demonstration Can The principle:

25 Laser 3D-Camera Overexposed and slow motion for demonstration Can The principle:

26 Laser 3D-Camera Overexposed and slow motion for demonstration Can The principle:

27 Laser 3D-Camera Overexposed and slow motion for demonstration Can The principle:

28 Laser 3D-Camera Overexposed and slow motion for demonstration Can The principle:

29 Laser 3D-Camera Overexposed and slow motion for demonstration Can The principle:

30 Laser 3D-Camera Overexposed and slow motion for demonstration Can The principle:

31 Laser 3D-Camera Overexposed and slow motion for demonstration Can The principle:

32 Laser 3D-Camera Overexposed and slow motion for demonstration Can The principle:

33 Laser 3D-Camera Overexposed and slow motion for demonstration Can The principle:

34 Laser 3D-Camera Overexposed and slow motion for demonstration Can The principle:

35 Laser 3D-Camera Overexposed and slow motion for demonstration Can The principle:

36 Laser 3D-Camera Overexposed and slow motion for demonstration Can The principle:

37 Laser 3D-Camera Overexposed and slow motion for demonstration Can The principle:

38 Laser 3D-Camera Overexposed and slow motion for demonstration Can The principle:

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86 Curl Wrinkle Dent Shape grayvalue ~ height information about depth of defects is available

87 Software

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89 Surface Inspection Software Shape Control Inspection of height Resolution (height) few 10 µm (!)

90 Summary Inspection at End of Line: Print Inspection Can Top Inspection Shape Control Even smallest defects can be detected in the surface in the range of few ten micrometer Of course fully automatized!

91 Thank you for your attention