A Real Time Nondestructive Crack Detection System for the Automotive Stamping Process

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IEEE Transactions on Instrumentation and Measurement, ISSN: 0018-9456, Vol: 65, Issue: 11, Page: 2434-2441

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Song, Joohyeb; Kim, Seulkirom; Liu, Zhenyi; Quang, Nguyen Ngoc; Bien, Franklin
Institute of Electrical and Electronics Engineers (IEEE); IEEE-INST ELECTRICAL ELECTRONICS ENGINEERS INC
Physics and Astronomy; Engineering; Acoustic emission (AE) test; automotive press panel; nondestructive examination; ratio conversion; real time crack detection
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This paper proposes a new method of detecting cracks caused by the automotive stamping process, through the use of a nondestructive, acoustic emission test. For a high quality and reliable automotive manufacturing process, continuous monitoring and crack detection methods based on nondestructive tests are required. In addition, it is necessary to employ an optimized method that adapts itself to the surrounding environment and to a facility's characteristics. The proposed approach is a comparative method using amplitude distribution between cracked and uncracked components. Since cracked components from the automotive stamping process release low elastic energy, a filter was employed that was set at a specific frequency band. An amplitude distribution method was applied along with ratio conversion to achieve a digitization. With the proposed analysis, it was possible to clearly distinguish between the cracked state and the normal state in an automated system environment, and the proposed analysis was verified in an actual automotive production line.