In the automobile production and manufacturing process, the coating process is particularly complex. The paint spraying process involves multiple processes such as primer, PVC, mid-coat (color paint), and top coating (clearcoat). Particles, shrinkage holes, and welding slag are prone to occur. , dirt and other various defects.
Due to the highly reflective properties of car body paint, traditional machine vision methods are difficult to image, and the automotive industry's paint surface defect detection is still highly dependent on manual labor.
However, manual inspection has many shortcomings, such as poor consistency in defect detection, frequent misjudgments and missed inspections, and difficulty in accurately tracing quality problems. Therefore, automotive OEMs have an increasingly urgent need for automated paint surface defect detection.
△PaintPro paint defect detection system
Shibit focuses on leading the transformation of smart manufacturing with "AI + 3D vision" innovative technology. It independently develops computational imaging + AI detection algorithms, successfully overcomes many technical problems in high-brightness surface defect detection, and launches the PaintPro paint surface defect detection system to realize complete vehicle inspection. High-precision online detection of paint surface defects helps OEMs improve the quality of painting processes and continue to reduce costs and increase efficiency.
01 Self-developed 3D deflection camera + AI algorithm
Accurately detect high-gloss surface defects
The PaintPro paint defect detection system is equipped with PaintPro Cam, a 3D deflection camera independently developed by SIBIT. It cooperates with multiple robotic arms to collect vehicle paint surface data online and perform parallel calculations to achieve accurate detection and detection of vehicle body paint surface defects. position.
△ PaintPro Cam 3D Deflection Camera
PaintPro Cam is a 3D camera based on phase deflection imaging technology, specially designed to solve the problem of mirror or mirror-like imaging. Based on deep learning computational imaging algorithms and self-developed high-frequency and high-brightness area array light sources, PaintPro Cam can achieve rapid detection and location of defects. In addition, the camera is also equipped with a self-developed 3D imaging algorithm, which can achieve high-precision surface reconstruction of high-brightness surfaces.
△ PaintPro Cam imaging results
With the support of PaintPro Cam, the PaintPro paint defect detection system can achieve stable and high-quality imaging of highly reflective car body paint. The minimum detectable defect size is 0.15mm, the detection rate is ≥98%, and online inspection of the entire car body paint can be completed within 60 seconds. Inspection, technical performance benchmarks against international first-tier brands, and meets the requirements of mainstream automobile OEMs for paint surface defect detection.
In addition, the PaintPro paint defect detection system can accurately locate the 3D coordinates of defects and transmit this information to the polishing robot to seamlessly integrate into the automatic polishing solution.
02 Digital twin virtual simulation
Dramatically shorten delivery cycle
The PaintPro paint defect detection system is equipped with the PaintPro Builder digital twin system independently developed by Shibit. It can establish a simulation scene that is consistent with the real production environment. By importing the car body CAD model, it can automatically generate collection points, plan the movement trajectory of the robotic arm, and simulate interference. area to achieve rapid verification of detection solutions in virtual environments.
Advanced digital twin technology effectively reduces on-site deployment time and significantly shortens debugging and delivery cycles.
03 Compatible with multiple models and colors
Supports online mixed inspection of paint surface defects
The PaintPro paint defect detection system supports online mixed inspection of paint defects in multiple colors and models. When a new car model is added, the CAD model of the new car model is imported and the deployment can be quickly completed through the digital twin system.
△New models are introduced and put into production quickly
04 Data statistical analysis function
Help optimize the quality of coating processes
△PaintPro Viewer software statistical analysis display
The operating terminal of the PaintPro paint defect detection system uses the self-developed PaintPro Viewer software to display the detected defect information, location distribution, cumulative quantity and trend charts in real time. The system also supports report generation and connection with the ERP system. Users can easily conduct defect analysis, trend monitoring and data statistics, providing a basis for automatic polishing and coating process optimization.
The PaintPro paint defect detection system will be officially put into production in the second quarter of 2023 and applied in the coating workshop of a well-known domestic automobile OEM. It can complete online detection of paint defects on the entire vehicle within 60 seconds, effectively solving the problem of low worker detection efficiency and unstable quality. The problem. In addition, the PaintPro system can count and analyze defect data offline, providing strong support for traceability and digital management of painting process problems.
△Customer application site of PaintPro paint defect detection system
In the future, Shibit will further explore and innovate, continue to overcome key technologies and problems in the field of visual measurement, and continue to promote quality control and intelligent manufacturing upgrades in the automotive industry.
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