Launched in September 1998, it’s an entirely new image analyzing method. A fully automatic real-time x-ray inspection system, it uses digital image processing in the complex field of pattern recognition. Intelligent computer software replaces the human observer and detects and classifies defects in radioscopic images. Defects like blowholes, pores, voids etc., which are not part of the constructive make-up of the inspected parts are found and corrected to prevent further errors. The software costs about US$200,000 and the hardware $400,000.

Ashley Stone, chief executive officer and president of Brampton, Ont.-based Jacobsen explains the system is more reliable and durable than a person.

“99.9% of the time equipment has a monitor with a person sitting in front of it looking at the images, looking for internal defects in cast aluminum wheels,” says Stone. “They decide which wheels will be inspected, look at the images and decide if the wheel is good or bad. If they decide it’s bad, the inspection cycle is interrupted and the wheel is forwarded on the bad conveyor, and destroyed.”

Without any prior information the Wheelinspector creates a flawless reference image from the actual image using a self-adapting algorithm. There are several advantages for in-line inspection. Filter parameters are easily set-up for new parts because there is no need for prior information. Online, real-time x-ray systems have to work at the highest possible speed, so computing an algorithm on more than one processor is important.

The system is easy to set up and operate, closes the control loop between defects and the cause at the foundry and can be used as a retrofit to most available real-time x-ray systems or can be embedded in a new system like MAXIwheel (machinery for automatic x-ray inspection of wheels).

Founded in Germany in 1987, Jacobsen moved its headquarters to Brampton in 1995 to be near its automotive customers.

Wheelinspector’s first Canadian installation went to Alcoa Wheel Products in Collingwood, Ont. A few month ago. The manufacturer of aluminum wheels was looking for a new wheel inspection system to replace a troublesome old unit.

“The decision was made because our equipment is getting older and we were having reliability problems. When it broke down, it was very hard to find parts,” explains Jeff Schwartz, foundry process engineering supervisor at Alcoa.

Alcoa has the system up and running, and is already noticing improvements. “Inspection speed is faster. We’re inspecting parts at around 26 seconds per wheel,” says Schwartz.

Putting in the new system was relatively painless, but because Alcoa was the first location there were a few bugs to work out of the software. The system had to be modified to meet Alcoa’s specs to recognize the parts and detect all defects.

If this technology delivers what it promises, cast wheel plants can look forward to eliminate rejects and rework, save valuable energy and reduce production costs. Better still, only good, lightweight and safer wheels will be rolling out of Canadian plants and onto our highways.