Das Expertennetzwerk der Fraunhofer-Allianz Vision zeigte auf den Fraunhofer Solution Days 2020 Exponate und Prüftechnologien für die Optimierung von industriellen Produktions- und Qualitätssicherungsprozessen. Die Technologien reichten von der virtuellen Planung und Simulation von optischen Inspektionsaufgaben, z. B. für die Prüfung von Montagebaugruppen und der Oberflächenqualität, über die markerfreie Nachverfolgung von Bauteilen bis hin zur zerstörungsfreien Prüfung. Das Fraunhofer IFF, Mitglied der Allianz Vision, stellte mit seiner Technologie OptoInspect 3D seine weltweit erfolgreich eingesetzte Lösung für eine 3D-Qualitätsprüfung von Bauteilen auf der Grundlage eines digitalen Zwillings vor. Ein Vortrag via Livestream im Auditorium für Technologiehighlights von Dr. Dirk Berndt, Leiter des Geschäftsfelds Mess- und Prüftechnik des Fraunhofer IFF, gab den Besucherinnen und Besuchern einen weiteren Einblick in die Bandbreite und Funktionsweise der Angebote der Allianz. Einen Mitschnitt des Vortrags finden Sie online unter https://youtu.be/6p7INozKp9U

1. © Fraunhofer
INLINE QUALITY INSPECTION CHECKUP
OPTIMIZATION OF PRODUCTION PROCESSES WITH MACHINE VISION
AND OPTICAL NON-DESTRUCTIVE MEASUREMENT AND TESTING TECHNOLOGY
Dr. Dirk Berndt
Dr. Dirk Berndt | Inline Quality Inspection Checkup
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2. © Fraunhofer
INLINE QUALITY INSPECTION CHECKUP
Optimization of Production Processes with Machine Vision
and Optical Non-destructive Measurement and Testing Technology
Dr. Dirk Berndt | Inline Quality Inspection Checkup
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INLINE QUALITY INSPECTION CHECKUP
AGENDA
1. Initial situation und motivation
2. Catalog of measures and checkup procedure
3. Technology examples for concrete action measures
 3D quality inspection with digital twin
 Virtual image processing for inline surface inspection
 Particle detection and classification directly on the component
 High-precision inline 3D measurement on plate-size surfaces
 Non-destructive testing using terahertz technology
 Software and hardware components for industrial X-ray and CT systems
 NDE 4.0 - The digital transformation of non-destructive evaluation
4. Service offers
Dr. Dirk Berndt | Inline Quality Inspection Checkup
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Inline Quality Inspection Checkup
Initial Situation and Motivation
Challenges
Impact on
production
Opportu-
nities of
digitali-
zation
Measures
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 Covid-19 pandemic increases
pressure on companies due to
growing costs and risks
 Increasing raw material prices,
individualization of products, etc.
 Which technologies do fit
for each individual need?
 Need for higher efficiency and
flexibility in production
 Introduction of new test methods
for product and process control
 Quality assurance process
 Digital transformation, such as …
 Digital twin
 Model-based engineering
 AI, data analytics

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Inline Quality Inspection Checkup
Catalog of measures and checkup procedure
Qualification
of employees
Self-
organization
and
automomy
Networking
and
integration
Assistance
system
Data
collection
and
processing
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1. Production flow chart
2. Process FMEA
3. Planning measures
4. Cost-effectiveness
analysis
5. Implemen-
tation of
measures
Technical accompaniment during
the entire development cycle
and support in regard to the
measures agreed upon

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INLINE QUALITY INSPECTION CHECKUP
AGENDA
1. Initial situation und motivation
2. Catalog of measures and checkup procedure
3. Technology examples for concrete action measures
 3D quality inspection with digital twin
 Virtual Image Processing for Inline Surface Inspection
 Particle detection and classification directly on the component
 High-precision inline 3D measurement on plate-size surfaces
 Non-destructive Testing using Terahertz Technology
 Software and hardware components for industrial X-ray and CT systems
 NDE 4.0 - The digital transformation of non-destructive evaluation
4. Service offers
Dr. Dirk Berndt | Inline Quality Inspection Checkup
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Inline Quality Inspection Checkup
3D quality inspection with digital twin
 Motivation and challenges:
 Individualization of products is an important megatrends of our time
 The consequence is a high variety of product variants
 Opportunities:
 Availability of digital product and process models
 The aforementioned forms of digitalization allow a flexible 3D quality
inspection up to lot size one
 Advantages for the applications:
 Reliability: functional safeguarding/coverage of the means of production,
nominal data generated directly from the digital model data
 Flexibility: work preparation is more automated (creation of test
programs, programming of procedures)
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Copyright: Fraunhofer IFF

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Inline Quality Inspection Checkup
3D quality inspection with digital twin
Test planning Accessibility Robot path
planning
Test result
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Inline Quality Inspection Checkup
Virtual image processing for inline surface inspection
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Virtual image processing for inline surface inspection
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 Defect models of technical surfaces: synthetic, stochastic, image based

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Particle detection and classification directly on the component
 Motivation
 Inline-inspection of cleanliness according to VDA 19
 Features
 Resolution 5 µm @ Image size 19 x 14 mm²
 Classification of particle size down to 20 µm
 Classification of particle type: metallic, non-metallic, fiber
 Advantages for the applications
 Quantitative detection of shape, position and amount of
contaminants on each component
 Results available immediately, enables inline-quality control
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High-precision inline 3D measurement on plate-size surfaces
 Motivation
 Measurement of large sealing surface in production speed
 High-precision 3D structure analysis
 Features
 Field of view in range of 15 x 15 mm² to 190 x 150 mm²
 Measurement accuracy axial < 1 μm (3σ), lateral down to 3 µm
 Measuring time < 0,1 s for 3D-image with 10 M. pixel
 Flexible work distance up to 300 mm
 Advantages for the applications
 100 percent production control for precision turned parts
 3D surface measurement in production process
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Non-destructive testing using terahertz technology
 Terahertz waves are safe and harmless to humans
 No special requirements due to radiation
protection
 Measurement technique is contactless and
non-destructive
 No coupling media required
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Testing of surfaces and inner structures of non metallic objects

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Inline Quality Inspection Checkup
Non-destructive testing using terahertz technology
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Inline inspection of automotive coating Inline testing of polymer object at
measurement rate of 20 kHz and
surface speed of 10 m/s

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Software and hardware components for industrial X-ray and CT systems
 The Fraunhofer EZRT has been researching
and developing industrial X-ray technology
for more than 20 years
 Enormous progress and new opportunities
in recent years
 ‚One-stop‘ service: Extensive know-how
in software and hardware
 Ideal partner for the planning and
implementation of production
process optimization projects
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Software and hardware components for industrial X-ray and CT systems
 Our expertise:
 Reconstruction and artifact
correction of CT data
 Software solutions for automatic
defect recognition (2D and 3D)
 System concepts for a wide
variety of applications
 Example: RoboCT system
 High flexibility and accessibility
by using robots with 6D degrees
of freedom
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NDE 4.0 - The digital transformation of non-destructive evaluation
 NDE technologies provide complex information on products and processes for I4.0 activities, but
different data formats and communication interfaces make integration into common industrial
networks hard to implement
 By implementing OPC UA as a new industrial communication standard and DICONDE as a general
data format in NDE devices, this information can generate considerable added value.
 Advantages:
 Controlling the sensors and their data on all abstraction levels, starting from factory floor up to
the cloud
 Developing of cognitive and IIoT-capable sensor systems
 From Big Data to Relevant Data for self-organizing production and optimization of the value
chain
 OPC UA and DICONDE: key technologies for NDE 4.0
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NDE 4.0 - The digital transformation of non-destructive evaluation
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Control level
Planning level
Field level
Actuator / sensor level
DICONDE sever
Archives meta, raw & measurement
data, (process) parameters, results, ...
Planning and optimization of processes
& specifications
Status and workload information
Control and operation of processes,
sensor systems, sensors & actuators
DICONDE
OPC UA
OPC UA-capable
Sensor system
(Actuator + sensors)
and
NDT electronics
Display of a result image on the
DICONDE server

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Service Offers
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Participatory design
and evaluation
Method and
technology
development
Technology
consulting and
training
Licensing of
technologies
and know-how
Realization of
turnkey
solutions
Customized solution
Pilot series
Prototype
Technology
demonstrator

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© Fraunhofer IFF
Contact:
Fraunhofer Vision
c/o Fraunhofer Institute for Factory Operation and Automation
Department Mesurement and Testing Technology
Dr.-Ing. Dirk Berndt
Phone: +49 391 4090-224
E-mail: dirk.berndt@iff.fraunhofer.de
www.vision.fraunhofer.de
INLINE QUALITY INSPECTION CHECKUP
OPTIMIZATION OF PRODUCTION PROCESSES WITH MACHINE VISION
AND OPTICAL NON-DESTRUCTIVE MEASUREMENT AND TESTING TECHNOLOGY
Dr. Dirk Berndt