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Proceedings of the 2002 IEEE

-
lntemationalConference on Robotics 8 Automation
Washington, DC May 2002

Reaction Force Inspection System Using Wavelet Transforms and Neural Networks
Yasuhiro Yamada Yoshiaki Komura Masanobu Masuda Yuuichi Ookubo
Fukui University Fukui University Industrial Technology Center Sanki, Inc.
of Fukui Prefecture
3-9-1 Bunkyo, 3-9-1 Bunkyo, 6 1 Kawaiwashizuka-choy 2 Kugamorinomiya,
Fukui-shi, Fukui-shi, Fukui-shi, Fushimi-ku,
Fukui 910-8507 Fukui 910-8507 Fukui 9 10-0 102 Kyoto 6 12-8495
JAPAN JAPAN JAPAN JAPAN
yyamada@mech.&kui-z4.ac.jp komura@mech.fikui-u.ac.jp

Abstract - This paper looks at a system for inspection


of the quality of a probe's reaction force characteristics.
This system, until now considered difficult to realize, 11. INSPECTION SYSTEM
automatesthe inspection method utilizing the touching of
an inspector's finger. Wavelet transformation and a The structure of the probe is shown in Fig. 1. With the
neural network (NN) approach is applied to the system inspection being done by the probe with the inspector's
for probes to learn an inspector's finger judgment. We finger touching, the sleeve of the probe is fixed and the
provide an input layer of a NN with thirty-three nodes inspector pushes the plunger with his fingertip. The inspector
corresponding to a time series of reaction forces of a is then determining the success or failure of the probe, by the
probe and an output layer with one node corresponding degree of the smoothness of the reaction force that his
to a judgment; being one of non-defective, defective, or fingertip feels from the plunger. In a probe inspection result
unable to judge. From experimental results, the if that results in a failure, there is a defective contact situation
effectivenessof the system has been clarified. between the compression spring and plunger or sleeve.
The inspection system is shown in Fig. 2. The
I. INTRODUCTION measurement head pushes the plunger of the probe, and the
reaction force from the plunger is measured with a force
Traditionally, skilled inspectors are used to inspect some sensor. The reaction force signals, measured by the force
products because automatic inspection is technologically sensor, are run through an amplifier, input to a data
difficult or too high in cost. Skilled inspectors have special acquisition system and are then stored in a personal
inspection skills acquired through an iterative training computer. Reaction force data were sampled at a rate of
process, an approach that is slow and time consuming. A 50000 ptsls.
skilled inspector uses five senses - vision, hearing, touch,
taste and smell, as they accord to the contents of the Helical compression spring
inspection being conducted. However, inspection accuracy
and speed, even of a skilled inspector, falls off with fatigue,
boredom, inattention, variability, and subjectivity.
The substitution of a skilled inspector by a real-time
automated inspection system would increase productivity
Plunger ' sleeve

and reliability. For example, automatic vision inspection Fig. 1. Structure of probe
systems have been developed for defect detection of glass
panels [I], sheet steel [2], aluminium strips [3] and web Measurement head
materials [4], with many of the systems in practical use.
In this paper, an inspection method is described for the
analysis of the quality of a probe's reaction force
characteristics. Its aim is to classify reaction force signals, as
the recognition of such signals is of particular interest in the
field of inspection. The classification we perform is based on
wavelet transform and a neural network, an approach needed
for inspections by probes in real time. The inspection system Con ter
evaluates the operative feeling of probes. Experimental system
results show that this method is suitable for such inspections. Fig. 2.Configuration of the inspection system

0-7803-7272-7/021$17.00 0 2002 IEEE 2563


Inspection Data The three reaction force signals shown in Fig. 3 seem
The dimensions and the spring constant of the probe almost identical at first glance. However, a skilled inspector
differ according to the probe type (A, B). The distance that recognizes the small differences in these signals by the
the measurement head pushes the plunger of probe A is set touch of his finger. The inspector judges a probe as
at 4mm, and in probe B at 2". Furthermore, deceleration non-defective by its smooth touch and he judges a probe as
of the measurement head in a downward motion is set to defective by its rough touch. The non-defective probe
-10.0 m / s 2 and acceleration of the measurement head in shows a smooth time series curve of the reaction force and
upward motion is set to 10.0 d s 2 for all probes. the defective probe a noisy, rough time series curve of the
Examples of the reaction force signals of the probes are reaction force.
shown in Figs 3-4. There are three classes of reaction force In the inspection process, the measurement head moves
signal; signals corresponding to defective parts, signals downward toward the plunger of the probe and the form of
corresponding to non-defective parts, and signals which are the reaction force signal stands when the measurement head
unable to judge as either defective or non-defective fiom contacts the plunger. The reaction force increases as the
the inspector's judgment. measurement head pushes the plunger of the probe.

3 0.8 I 1
2.5 1 0.7 1 I
0.6
h

g 0.5
-
0.4
8 0.3
-
.g 0.2
-
; 0.1
42
-
= O J
-0.1 10 20 30 40 50 60 ?O
20 40 60 80 100 120 140
-0.5 A l
".L
Time (msec) Time (msec)
(a) Inspector'sjudgment for probe A02 : non-defective (a) Inspector'sjudgment for probe B10 :non-defective
3 0.8

0.7
2.5 }
0.6
h
0.5
v
W 0.4
8
8 0.3

Y
.4
E 0.2
2 0.1

$ 0

-0.5
20 40 60
Time (msec)
80 100 120 140
-0.1

-0.2 ' Time (msec)


(b) Inspector'sjudgment for probe A05 : unable to judge (b) Inspector'sjudgment for probe BO3 : unable to judge
0.8 1 I
0.7
2.5 t I 0.6

5
h

0.5
8 0.4
8
s 0.3
.A
%
U
0.2
0.1
W O

-0.5
20 40 60 80 100 120 140
-0.1
-0.2 '
10 20 30 40 50 60
II
lo
Time (msec) Time (msec)
(c) Inspector'sjudgment for probe A03 : defective (c) Inspector'sjudgment for probe BO8 : defective
Fig. 3. Examples of inspection results of probe A Fig. 4. Examples of inspection results of probe B

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After the measurement head has moved to the limit of its
stroke it then recedes. The reaction force decreases as the
measurement head recedes, and moves to zero when the
measurement head parts from the plunger.
A test signal database is used to train a neural network for
automated inspection.

111. INSPECTION PERFORMANCE

Wavelet transforms
Wavelet transformation is now recognized as a useful
tool for various signal processing applications [SI.
In this paper, the Spline-Wavelet fhction is used to
process the reaction force signals, and is given by

where m is the wavelet order and mEZ (an integral set). The
force sensor produced a reaction force signal F(Q at the t th
time instant. The gradient of the reaction force is expressed
as follows:

dF(t) = F ( t )- F(t - 1)

An example of wavelet transform of a d F ( . is shown in


(2)
- 33 Features

'p
.)
1

output

Fig. 6. Structure of the neural network

In our experiment, a data set (probe types A and B) was


used to train the NN, and a test data set (probe types A and
B) was used to test the performance of the NN.
The test results are shown in Table 1 and 2. The test
results from 20 probes demonstrate the usefulness of this
approach for reaction force inspections by probes.

I
Table I Test results of probe A

NO. I Inspector's I NN'S ]


Output layer

Fig. 5. As a result, three wavelet coefficients (j=4,5,6) can


represent features of the analysed signal.

Neural network
Features of the signal are selected from three wavelet
coefficients (j=4,5,6). We provided an input layer of NN
with 33 nodes that corresponded to the features of a time
series of reaction forces of the probe and the output layer
with one node corresponding to the judgment. Three time *: nondefective (0.0) ,unable to judge (OS), defective (1 .O)
series data (j=4,5,6) are classified into 11 classes by their
amplitudes. Then the number of data in each class forms the
input for the 33 nodes of the input layer of the NN (see Fig. Table 2 Test results of probe B

i=O

i=1
i=2
i=3
i=4

j=5

i=6

j= 7
*: nondefective (0.0) , unable to judge (0.5), defective (I .O)
i=8

Fig. 5. Wavelet approximations of the wavelet transform using the


Spline of the gradient of the reaction force

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IV. CONCLUSIONS REFERENCES

In this paper we have considered reaction force [l] J. Wilder, "Finding and evaluating defects in glass",
inspections utilizing probes. The inspection results of Machine Vision for Inspection and Measurement,
skilled inspectors were leamed by the proposed Academic Press, 1989, pp. 231-255.
wavelet-neural network system. The leamed wavelet-neural [2] J. Olsson and S . Gruber, "Web process inspection
network system arrived at the same inspection results as a using neural classification of scattering light",
skilled inspector in 95% of inspections. In time better Proceedings of the IEEE Intemational Conference on
trained neural networks will M e r improve the speed and Industrial Electronics, Control, Instrumentation and
accuracy of probe inspections, thereby reducing inspection Automation (IECON'92), San Diego, 1992, pp.
costs. 1443-1448.
[3] C. Femandez, C. Platero, P. Campoy, and R. Aracil,
ACKNOWLEDGMENT "Vision system for on-line surface inspection in
aluminium casting process", Proceedings of the IEEE
This research has been supported in part by the Japan Intemational Conference on Industrial Electronics,
Society for the Promotion of Science. Control,Instrumentation and Automation (IECON'93),
Maui, HA, 1993, pp. 1854-1859.
[4] D. Brzakovic and N. Vujovic, "Designing defect
classification system : a case study", Pattem
Recognition, 29, 1996, pp. 1401-1419.
[5] G. Strang and T. Nguyen, Wavelets and Filter Banks.
Cambridge, U.K.: Wellesley-Cambridge Press, 1996.

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