This project is dedicated to development of diagnosis system of the mild steel
surface damage or deformation and compatibility solutions to enable high
productivity due to protect surface damage in advance and save production loss
by automatic surface quality control system. The basic technical objective of
this project is research and development of major compatibility issues between
surface condition of low carbon steel surface and its digital image analysis by
morphological interpretation of color, shape, and texture of surface damage in
real time. This project is to demonstrate, by way of simulation tests of image
analysis by the Light Section Profiling System (LSP system) in high-speed
production process for surface defects, the tradeoffs associated with
conflicting requirements of surface condition, for surface deformation from high
stress or temperature of production process, surface defect from corrosion
inhibition and materials fatigue life, wear resistance and corrosion resistance
with lubricant for process of milling, forging, pressing, etc. The anticipated
results of the project comprise key components of an advanced technology of
diagnosis system of surface damage analysis and methodology of study of surface
defect with mechanical properties. The project will result with: image capture
and database establishment procedures for surface damages, data expert system
with data query management, methodology of digital image analysis of
morphological defects, classification methods of defined images, automatic
on-line prognosis system for surface damage. The methodologies and experimental
data that are conceived for the proposed investigation will allow selection of
optimal condition of surface quality control and shape deformation up to 1,000 m/min
of process speed.
This system can apply to the continuous high-speed steel production process for
detection and prevention of surface damage or outside defect of products. It
will prevent the claim of products and increase the productivity of company,
which are producing final stage of steel sheet relating to surface. The
superiority of this system is that 3 main digital image elements (color, texture,
and shape) can combine for image detection case by case and define by
multi-dimensional classification method for preparation of optimal decision. And
it can adapt easily to user's hardware with low cost of image capture system.
LSP system in on-line will be powerful for detection of surface damage and
automatically can save all data to user's main computer that are interpreting
data of database.
Digital image analysis, Image capturing system, Export system, Morphology,
Surface damage, On-line Diagnosis, Multi-dimension classification, Light Section
Profiling System (LSP system), Corrosion
The Light Section Profiling System (LSP system) is intended for in-process
detection topographical irregularities of plane steel sheets. The principle
scheme of the system is presented on the Fig..1.a. The steel sheet 1 is
illuminated by gapped light source 2. When the object is illuminated in the
field of vision of object lens a reflected gap image is observed. If the surface
is flat and smooth the gap image is looking as a straight line (Fig.1.b). In
case of presence irregularities such as cracks, scratches, tear out of metal or
holes, the shape of the line is changed (Fig. 1.b). As result the reflection
position of light source on the investigated surface is changed. The optical
system receives the reflected light and projects it on the diode matrix 3. If
the reflected light came from the some peak on the surface it fall on the area
above middle line of detectors. In case of reflecting from a cavity the beam is
come to the area below the middle line. The position of detectors can be
adjusted to fit a range of normal deviations of surface defects. In that case
any signal coming from the upper or lower lines of detectors will inform about
out of size range of surface defects. The information can be used for future
processing by control system.
The described base system can be modified for processing information about color
heterogeneity of controlled surface. Corrosion, oil stains or temper color can
cause such heterogeneity. For detection these defects the reflected passed throw
optical split system (4,5). Additional detectors 6 analyze the spectrum of
reflected light. The conclusion is made by analysis of relative intensity of red,
green and blue spectral components of reflected light.
The system is fully designed on analog electronic components. It is allow
achieving data processing in real time with speed of steel sheet movement up to
Fig.1 a) General scheme of LSP system: 1 steel sheet; 2 light source; 3
detectors of position of reflecting surface; 4 light beam split system; 5
dispersion prism; 6 detectors of reflected light dominant color; b) view of
gapped light source on smooth and flat surface; c) view of gapped light source
on rough surface.
If we want to evaluate more micro-surface damage by using this system, we can
combine with the linnik double microscope system as following;
The Linnik double microscope with two separate mutually facing oblique parts,
one is illuminating and the other is optical, supports a significantly broader
range of analysis of the depth of damage (Fig.2).
When an object is illuminated through the slot diaphragm in the lens field of
vision a surface shadow profile is observed. This method allows measuring damage
3 to 100 mm deep with accuracy of the order of 3-5%. Special optical attachments
may expand the upper range of measurements to 1 mm.
Fig. 2. Linnik optical double microscope configuration: 1, 2 tube; 3 lens; K
ocular; a slot collimator; HH plane of observation; а1 image of slot а;
а2 projection, а1'; a2 same when plane НН shifts to distance d; j -- angle
of deviation of tubes 1 и 2 from normal С.
Scope of project
Refer to proposal 1.