Asia Rubtech Expo 2018 Non Destructive Testing of tires by Shearography

Transcription

1 Non Destructive Testing of tires by Shearography SDS Systemtechnik GmbH Stefan Dengler Germany

2 CONTENTS - Introduction - Interferometric Tire Inspection Milestones - Tire Testing with Shearography today - Tire Testing with Shearography: What next?!

3 SDS Systemtechnik GmbH facility with administration, assembling and production (total 3000m²) 20 employees at SDS in Germany: - 6 administration and after sales support - 4 construction and development (soft- and hardware) - 10 production and assembly, installation and support and 3 apprentices (electro mechanics and commercial) more then 500 installed systems

4 SDS Product Range - Interferometric Tire Tester for new tire production, R&D and retreading of all type of tires - Laser Marking Systems semi- and fully automated systems for OEM applications Handheld-Systems for OTR and Agriculture Tire Industry - 2-D Measuring Systems and Color Detection Profile Measurement offline and inline Inline Tread Length Measurement systems, Splice verification,.. Color Line Detection inline and offline Layer Check System - 3-D Contouring Systems PTS - pressure test system for casing inspection in the Retread Industry EMS - monitoring system for durability test, high speed test,. CMS - automatic wear measurement of Aircraft Tire

5 InterferometricTireTester for all tire applications: Machine control Result verification - from 8 inner diameter up to 63 - up to 1800 mm tire width and 7 ton weight - from manual to fully automatic testing ITTEasy type 1280 Truck tire retreading ITT-1 type 1280,1680 R&D, retreading New Tire Production ITT-2 type 1080, 1280, 1680 New tire production and industrial retreading ITT-OTR up to 63 tires R&D, retreading New Tire Production

6 Laser Marking Systems individual codes or numbers, data, graphics, barcodes easy to operate fast and reliable

7 Fully Automated for - higher capacity - better efficiency - inline with ITT, X-Ray or conveyor system

8 PM-offline PM-inline Modern techniques => Touch screen, mobile system, optimized spare part handling, online service

9 From Asia Rubtech Expo 2018 From Construction over Production to the Final Product out of one Hand! Installation and After Sale Support together with the Worldwide SDS Network

10 Representatives and Services: Central Marketing North- and South America, Canada SDS China office China Illies Japan Jugi Corp. Korea Newera Asean VENTURE INSTRUMENTATION TECHNOLOGIES PVT LTD. A-205, 1st Floor, Block III, KSSIDC Complex, Electronic City Phase 1, Bangalore Phone : , ,

11 Interferometric Tire Inspection Milestones

12 Dennis Gabor 1971 first double puls Hologram of a tire (Goodyear, Akron)

13 1973 IHI (USA) designed the first Holographic Tire Tester (+ $ ) with film and gas-laser Test time: 10 min/tire + long relaxation Tires must be manually spreated Manual tire loading and centering with crane Manual positioning of measuring head Chemical processing of the film and offline verification

14 1993 LTI (USA) developed the first shearing interferometer with electronic camera Test time: 8 min/tire (bead to bead) Manual loading by rolling in/out The filmless system reduced the cost per tire significant Bead to bead inspection with vertical test position of the tire!

15 1998 SDS started with the serial production of industrial tire test systems Vergölst, Bad Nauheim At that time one of the largest retreaders in Europe For initial inspection and partly final inspection Test time: 2 min/tire crown only 5 min/tire bead to bead Innovation: Introduction of multiple laser diodes to mimimize operation cost and downtime Automated tire handling with conveyor system Automatic positioning of measuring head Barcode System to identify production number for archiving and traceability

16 tire testing with Shearography today

17 ITT systems in new tire applications and retreading: (1998 August 2018) Retreading 286 truck tire 4 OTR tire 37 aviation tire New tire + R&D 147 regular tires 7 OTR and agriculture tire 3 aviation tire Today about half of the machines are in new tire applications 2007 only ~ 27%

18 Application of ITT systems: Area number application ratio retread vs new tire Europe 110 Retread 30 New Tire USA, Canada 162 Retread and Mexico 32 New Tire 3,6x 5x more retread Japan 6 Retread 8 New Tire China 8 Retread 40 New Tire 1,3x 5x more new tire India 2 Retread 12 New Tire 6x

19 with the industrial application of Shearography the focus goes to: - Test capacity or Cycle Time per tire - Cost per tire and - Standardization of test conditions and validation - Automated material, test - and result handling

20 Cycle Time per Tire previously film-based Interferometry and Shearography with B/W film today film-less Speckle-Shearing with digital cameras - No chemical process with film - Instant test result directly after test is completed - Short exposure time and fast data transfer with CMOS and GigE - Automatic tire handling and multiple cameras ( and machines ) Cycle time: 1973 ~ 10 min (not including film processing, offline) (bead to bead) 1998 ~ 6 min today 2018 ~ 1 min (Twin machine setup)

21 Twin machine : less than 1min per Tire, bead to bead 2 Triple head machines 1x center camera for crown only, no tilt 2x sidewall cameras 1. Cycle: first half of crown first sidewall (a) 7a 6a 8a 1 4 1a 2 3 2a 3a Turn over fixture between 2. Cycle: 8 second half of crown second sidewall (b) 2b 3b 1b 5 8b 7 6 2b 6b 5a 4a 4b 5b

22 Inspection Cost per Tire previously Interferometry and Shearography with Gas-Laser today => This electronic was High Speckle-Shearing tech for physicist with CMOS camera and Laser-Diodes => still High tech but low skill - No consumables (film, chemicals, etc.) - Less maintenance, less downtime - Less electric energy consumption for laser: ~ 20 kw -> ~ 1 W vacuum system: ~ 4.6 kw -> ~ 2 kw - Longer laser lifetime: from ~3000h today typically more than 20000h Cost per tire(not including depreciation) 1973 ~ 10, ~ 0,05 to 0,15 today 2018 ~ 0,02 to 0,05

23 Standardization of test procedure and validation To get a reproducible test result: - test conditions and parameters have to be defined and controlled ( within one organization or even in the industry ) SDS provide Automated Processes To get a reproducible validation - Criteria have to be defined ( anomaly library ) - Operators have to be skilled SDS provide Automated Evaluation to reduce variance of manual measurement

24 How to do a traceable and repeatable validation of a test result? Test result with correlating separation

25 Simplified Solution for an operator independent evaluation by an semi automated validation of anomalies Flexible evaluation zone (within the green borderlines) moved over critical area by the operator Evaluation done by software with predefined criteria

26 or fully automatic detection of anomalies by Software into an automated processing for a repeatable and traceable validation Findings are listed in a table: - automated classification - sorting on conveyor - statistical evaluations, etc:

27 for an fully automatic detection with tire zones the contour of every tested tire is required Calculation of tire contour based on: Tire data Rim radius Outer radius Bead height Shoulder height Machine parameter Opening angle of viewing field (lens) Camera position relative to tire center

28 Automatic Tire Contour Detection (TCD) Verification before loading into tire test system Interface with process control to match tire information for test result handling Measuring complete tire contour for - Correct positioning of all cameras (triple head bead to bead operation) - Calculation of evaluation zones for Automatic Anomaly Detection (AAD) TCD module attached to vacuum chamber Result of contour measurement with computed main dimensions for positioning

29 Computation of tire zones in crown scan Tire zones crown Tire zones crown superpositioned over sector image

30 Computation of tire zones in sidewall scan Tire zones sidewall Tire zones crown superpositioned over sector image

31 Automatic Anomaly Detection combined with Tire Contour Detection Tire zones for crown and sidewall super positioned over sector image - for automated evaluation with different criteria - for eliminating overlap in automatic evaluation

32 Automatic Anomaly Detection combined with Tire Contour Detection Test result validated with different criteria depending on zone

33 Automatic Anomaly Detection combined with Tire Contour Detection Correlating tire picture (video image) with marked findings for further analysis

34 Automatic Anomaly Detection combined with Tire Contour Detection TCD cost & labour saving benefits Eliminates manual creation of test settings (manual settings are still applicable on SDS systems) Eliminates problems due to incorrect selection of test settings upon tire loading Simplifies interface to database and barcode systems (only tire ID must be provided) Can be retrofitted to existing tire test systems TCD result output benefits Head positioning is adapted to each individual tire All results are calibrated All results show correct location of tire zones (crown, shoulders, sidewalls) Automatic anomaly detection is executed tire zone specific Avoidance of anomaly detection outside regions of interest

35 tire testing with Shearography what next?!

36 Next step is to improve result validation Upper Sidewall Crown Lower Sidewall Complete result map in one view with elimination of overlap and indication of missing areas Superposition with construction data (CAD) and position of components (belt edges etc.) for a more detailed classification depending on position of anomaly in the tire construction and how? [mm] Defect map of unwrapped tire

37 with the measuring of the cross section of a tire by TCD the next step is the calculation of a 3D model

38 Display of tire map as polar diagram Data from both sidewalls of the tire are unwrapped and displayed by computation

39 Example 1: Sector Images (current way) upper sidewall crown lower sidewall

40 Example 1: Tire Map (next generation)

41 Example 2: Sector Images upper sidewall crown lower sidewall

42 Example 2: Tire Map

43 Example 2: Tire Map Validation of findings corresponding to predefined criteria an position

44 Example 3: Sector Images upper sidewall crown lower sidewall

45 Example 3: Automatic Anomaly Detection in tire map flaw detected in crown and upper sidewall scan flaw detected in crown and lower sidewall scan

46 Benefits of Shearing Result Mapping All-in-one bead to bead view Elimination of image areas outside of tire Elimination of overlap areas in adjacent sector images Correct display of flaws across sector borders and across scan sections Automatic detection of flaws across sector image borders Benefits of tire contour projection into sector images (patent pending) Simple setup standard in actual machines Combination with automatic measuring head positioning No extra scan or process time required

47 For the possible to emerge, the impossible must always be tried Asia Rubtech Expo 2018 SDS Systemtechnik GmbH 20 th anniversary For the possible to emerge, the impossible must always be tried Hermann Hesse (born in Calw) in a letter to his cousin Wilhelm Gundert Grandfather was Hermann Gundert ( ), a missionary in India Thank you for your attention!!