Patent Description:
In welding, portions of two or more members are joined to each other by melting. The welded members are inspected for whether or not the welded portion (hereinbelow, called the weld portion) is appropriately joined. For example, in a non-destructive inspection, a human (an inspector) that grips a detector causes the detector to contact the weld portion. An ultrasonic wave is transmitted from the detector toward the weld portion, and data related to the welding object is derived based on the reflected waves. Technology that can increase the accuracy of the data related to the welding object of the non-destructive inspection is desirable.

<CIT> discloses a field system that can be deployed in the application of pipe welding and resulting welded pipes. The field system may include, for example, internal welding systems, tie-in welding systems, pipe inspection systems, pipe handling systems, internal pipe cooling systems, non-destructive testing systems, as well as remote interface and database systems.

<CIT> discloses a three-dimensional ultrasonic inspection apparatus including: a sensing device for ultrasonic inspection including an ultrasonic sensor as a transducer, in which a plurality of piezoelectric vibrators are disposed in a matrix or an array; a drive element selecting unit for selecting and driving a piezoelectric vibrator for producing an ultrasonic wave among the ultrasonic transducer; a signal detecting circuit for detecting the electric signal of the reflected echo by receiving the reflected echo from the joined area; a signal processing unit for subjecting the electric signal to signal processing and generating three-dimensional imaging data by causing the electric signals to correspond to mesh elements in a three-dimensional imaging region of the object to be inspected; and a display processing device for displaying the detection results and three-dimensional image data from the signal processing unit, while detecting the size and the position of the molten-solidified portion, and the size and the position of the weld defect of the joined area, from the intensity distribution of the three-dimensional imaging data generated by the signal processing unit.

<CIT> discloses a method for inspecting a joined region and joining strength of a joined object formed by a spot friction stir joining process. An ultrasonic wave is introduced into the joined object from a backing face opposed to a joining tool plunging face and the ultrasonic wave reflected from the joined object is taken in. The joining region and the joining strength is estimated by observing a reflected wave of the ultrasonic wave in the vicinity of a position, along a reference direction, corresponding to an interface of two joining members, without using the reflected wave of the ultrasonic wave reflected from the joining tool plunging face, thereby inspecting the joined object based on the estimation result.

<CIT> discloses ultrasonic inspection of a spot welded part using a robot. The posture and position of an ultrasonic sensor with respect to a workpiece are changed by the robot, an ultrasonic wave is transmitted to the workpiece in a plurality of postures at a plurality positions with respect to one spot welded part, the posture and position becoming maximum in the intensity of a reflected wave among a plurality of the postures and positions are detected and the quality of the spot welded part is decided using the measuring data of the ultrasonic sensor in the detected posture at the detected position.

A problem to be solved by the invention is to provide a processing system (<NUM>), a processing method, a program, and a storage medium that can increase the accuracy of data related to a welding object.

The present invention provides a processing system (<NUM>), in accordance with claim <NUM>.

The present invention also provides a measurement method in accordance with claim <NUM>, a program in accordance with claim <NUM> and a storage medium in accordance with claim <NUM>.

Embodiments of the invention will now be described with reference to the drawings.

The drawings are schematic or conceptual; and the relationships between the thickness and width of portions, the proportions of sizes among portions, etc., are not necessarily the same as the actual values. The dimensions and proportions may be illustrated differently among drawings, even when the same portion is illustrated.

In the specification and drawings, components similar to those already described are marked with the same reference numerals; and a detailed description is omitted as appropriate.

<FIG> is a block diagram illustrating a configuration of a processing system according to an embodiment.

As illustrated in <FIG>, the processing system <NUM> according to the embodiment includes a processing device <NUM> and a memory device <NUM>. The memory device <NUM> stores data related to a weld inspection. The processing device <NUM> processes the data related to the weld inspection.

The processing system <NUM> illustrated in <FIG> further includes a detector <NUM>, an input device <NUM>, and a display device <NUM>. The detector <NUM> transmits an ultrasonic wave toward an object and detects (receives) the reflected wave. The detector <NUM> includes, for example, a probe. Hereinafter, the transmission of the ultrasonic wave and the detection of the reflected wave by the detector <NUM> are called a probe (probing).

The processing device <NUM> performs various processing based on the detected reflected wave. The processing device <NUM> causes the display device <NUM> to display a user interface. The user can easily check data obtained by the processing via the user interface displayed by the display device <NUM>. The user can input data to the processing device <NUM> via the user interface by using the input device <NUM>.

The processing device <NUM> is connected to the memory device <NUM>, the detector <NUM>, the input device <NUM>, and the display device <NUM> via wired communication, wireless communication, or a network.

Here, the weld inspection will be described in detail. A non-destructive inspection of the weld portion is performed in the weld inspection.

<FIG> is a schematic view illustrating a state of the non-destructive inspection.

The detector <NUM> includes multiple detection elements for inspecting the weld portion. For example, the detector <NUM> has a configuration that can be gripped by the hand of a human as illustrated in <FIG>. The human that grips the detector <NUM> inspects a weld portion <NUM> by causing the tip of the detector <NUM> to contact the weld portion <NUM>. Here, an example will be described in which a human grips the detector <NUM> and performs a weld inspection. Hereinafter, the human (e.g., the inspector) that grips the detector <NUM> and performs the weld inspection is called the user.

<FIG> is a schematic view illustrating the internal structure of the detector tip.

As illustrated in <FIG>, an element array <NUM> that includes multiple detection elements <NUM> is located inside the detector <NUM> tip. The detection elements <NUM> are, for example, transducers. For example, each detection element <NUM> emits an ultrasonic wave of a frequency of not less than <NUM> and not more than <NUM>. The multiple detection elements <NUM> are arranged in a first direction and a second direction that cross each other. In the example illustrated in <FIG>, the multiple detection elements <NUM> are arranged in an X-direction and a Y-direction that are orthogonal to each other.

For example, the element array <NUM> is covered with a hard propagating member <NUM>. The hard propagating member <NUM> is positioned between the element array <NUM> and the weld portion <NUM> when the tip of the detector <NUM> is caused to contact the weld portion <NUM>. The hard propagating member <NUM> includes a resin material or the like through which an ultrasonic wave easily propagates. By providing the hard propagating member <NUM> that corresponds to the shape of the surface of the weld portion <NUM>, the ultrasonic wave easily propagates into the interior of the weld portion <NUM>. Deformation, damage, etc., of the element array <NUM> can be suppressed by the hard propagating member <NUM> when the detector <NUM> contacts the weld portion <NUM>. The hard propagating member <NUM> has a hardness sufficient to suppress the deformation, the damage, etc., when contacting the weld portion <NUM>.

<FIG> and <FIG> illustrate a state of inspecting a member <NUM> as the welding object. The member <NUM> is made by spot-welding a metal plate <NUM> (a first member) and a metal plate <NUM> (a second member) at the weld portion <NUM>. As illustrated in <FIG>, a solidified portion <NUM> is formed at the weld portion <NUM> by a portion of the metal plate <NUM> and a portion of the metal plate <NUM> melting, mixing, and solidifying.

For example, in the inspection, it is verified whether or not the weld portion <NUM> is formed. In the inspection, it is verified the diameter of the weld portion <NUM>, whether or not the diameter is sufficient, etc. A couplant <NUM> is coated onto the surface of the object when inspecting so that the ultrasonic wave easily propagates between the object and the detector <NUM>. Each of the detection elements <NUM> transmits an ultrasonic wave US toward the member <NUM> coated with the couplant <NUM> and receives reflected waves RW from the member <NUM>.

Or, instead of the couplant <NUM>, a soft propagating member through which the ultrasonic wave easily propagates may be located at the tip of the detector <NUM>. The soft propagating member is softer than the hard propagating member <NUM>. The soft propagating member deforms along the shape of the surface of the weld portion <NUM> when contacting the weld portion <NUM>. The soft propagating member includes, for example, a gel resin.

For example, as illustrated in <FIG>, one detection element <NUM> transmits the ultrasonic wave US toward the weld portion <NUM>. A portion of the ultrasonic wave US is reflected by the upper surface or the lower surface of the member <NUM>, etc. The multiple detection elements <NUM> each receive (detect) the reflected waves RW. The detection elements <NUM> sequentially transmit the ultrasonic wave US; and the reflected waves RW are detected by the multiple detection elements <NUM>.

When the detection result of the reflected waves is obtained, the processing device <NUM> performs the following first and second determinations. In the first determination, the processing device <NUM> determines whether or not points of the welding object are joined based on the obtained detection result. In the second determination, the processing device <NUM> sets a first region based on the points determined to be joints. The processing device <NUM> calculates the circularness of the first region and uses the circularness to determine an appropriateness of the result of the first determination. The circularness indicates the shape of the first region and the degree of similarity with a circle. For example, the shape of the first region approaches a circle as the value of the circularness increases.

The first determination and the second determination will now be described in detail.

<FIG> is schematic views for describing processing according to the processing system according to the embodiment.

As illustrated in <FIG>, a portion of the ultrasonic wave US is reflected by an upper surface 11a of the metal plate <NUM> or an upper surface 13a of the weld portion <NUM>. Another portion of the ultrasonic wave US enters the member <NUM> and is reflected by a lower surface 11b of the metal plate <NUM> or a lower surface 13b of the weld portion <NUM>.

The positions in the Z-direction of the upper surface 11a, the upper surface 13a, the lower surface 11b, and the lower surface 13b are different from each other. In other words, the distance in the Z-direction between the detection element <NUM> and these surfaces are different from each other. The peaks of the intensities of the reflected waves are detected when the detection element <NUM> receives the reflected waves from these surfaces. Which surface reflected the ultrasonic wave US can be verified by calculating the time until each peak is detected after transmitting the ultrasonic wave US.

<FIG> are graphs illustrating the relationship between the time after transmitting the ultrasonic wave US and the intensity of the reflected wave RW. In <FIG>, the vertical axis is the elapsed time after transmitting the ultrasonic wave US. The horizontal axis is the intensity of the detected reflected wave RW. Here, the intensity of the reflected wave RW is illustrated as an absolute value. The graph of <FIG> illustrates the detection result of the reflected waves RW from the upper surface 11a and the lower surface 11b of the metal plate <NUM>. The graph of <FIG> illustrates the detection result of the reflected waves RW from the upper surface 13a and the lower surface 13b of the weld portion <NUM>.

In the graph of <FIG>, a peak Pe11 occurring first is based on the reflected wave RW from the upper surface 11a. A peak Pe12 occurring second is based on the reflected wave RW from the lower surface 11b. The times at which the peak Pe11 and the peak Pe12 are detected correspond respectively to the positions in the Z-direction of the upper surface 11a and the lower surface 11b of the metal plate <NUM>. A time difference TD1 between the time at which the peak Pe11 is detected and the time at which the peak Pe12 is detected corresponds to a distance Di1 in the Z-direction between the upper surface 11a and the lower surface 11b.

Similarly, in the graph of <FIG>, a peak Pe13 occurring first is based on the reflected wave RW from the upper surface 13a. A peak Pe14 occurring second is based on the reflected wave RW from the lower surface 13b. The times at which the peak Pe13 and the peak Pe14 are detected correspond respectively to the positions in the Z-direction of the upper surface 13a and the lower surface 13b of the weld portion <NUM>. A time difference TD2 between the time at which the peak Pe13 is detected and the time at which the peak Pe14 is detected corresponds to a distance Di2 in the Z-direction between the upper surface 13a and the lower surface 13b.

The processing device <NUM> determines whether or not the time difference between the peaks corresponds to the thickness of the weld portion <NUM>. When the time difference between the peaks is determined to correspond to the thickness of the weld portion <NUM>, the point is determined to be joined. For example, the processing device <NUM> compares the time difference between the peaks to a preset threshold at points in the X-Y plane. When the time difference is not less than the threshold, the processing device <NUM> determines that the point is joined. When the time difference is less than the threshold, the processing device <NUM> determines that the point is not joined. The threshold is set based on the thickness of the weld portion <NUM>. A range may be set instead of the threshold. The processing device <NUM> determines that the point is joined when the time difference is within the range.

The intensity of the reflected wave may be represented in any form. For example, the reflected wave intensity that is output from the detection element <NUM> includes positive values and negative values according to the phase. Various processing may be performed based on the reflected wave intensity including the positive values and the negative values. The reflected wave intensity that includes the positive values and the negative values may be converted into an absolute value. The average value of the reflected wave intensities may be subtracted from the reflected wave intensity at each time. Or, the weighted average value, the weighted moving average value, or the like of the reflected wave intensities may be subtracted from the reflected wave intensity at each time. The various processing described in the application can be performed even when the results of such processing applied to the reflected wave intensity are used.

<FIG> is drawings for describing the processing according to the processing system according to the embodiment.

<FIG> is a plan view schematically illustrating the weld portion <NUM> vicinity. For example, it is determined whether or not points of a detection area DA illustrated in <FIG> are joined based on the reflected waves detected by the detector <NUM>.

<FIG> illustrates an example of the detection result at points of a line segment Li1 illustrated in <FIG>. In <FIG>, the vertical axis is the position in the Z-direction perpendicular to the X-direction and the Y-direction. The horizontal axis is the position in the X-direction. In <FIG>, ∘ (the white circles) illustrate the position in the Z-direction of a first reflecting surface of the member <NUM>. The first reflecting surface is the upper surface 11a of the metal plate <NUM>, the upper surface 13a of the weld portion <NUM>, etc. • (the black circles) illustrate the position in the Z-direction of a second reflecting surface of the member <NUM>. The second reflecting surface is the lower surface 11b of the metal plate <NUM>, the lower surface 13b of the weld portion <NUM>, etc. As described above, these positions are calculated based on the time after transmitting the ultrasonic wave US until the peak of the reflected wave RW is detected. In <FIG>, ◆ illustrate the determination result of the joint and the non-joint. The points that are determined to be joined are illustrated by the value of <NUM>; and the points that are determined to be non-joints are illustrated by the value of <NUM>.

<FIG> is an example of an image illustrating the processing result of the processing system according to the embodiment.

According to the method described above, the first determination of determining whether or not the points of the detection area DA are joined is performed. The processing device <NUM> generates, for example, the image illustrated in <FIG> based on the result of the first determination. In <FIG>, white shows that the point is joined. Black shows that the point is not joined. A first region R1 that is based on a cluster of white spots corresponds to the weld portion <NUM>. A second region R2 that is based on a cluster of black spots corresponds to the member <NUM> around the weld portion <NUM>.

The processing device <NUM> may determine the goodness of the weld of the welding object based on the surface area of the first region R1. The processing device <NUM> may calculate the surface area of the weld portion <NUM> based on the surface area of the first region R1. The processing device <NUM> may calculate the diameter of the weld portion <NUM> based on the diameter of the first region R1. For example, the distances between the detection elements <NUM> are prestored in the memory device <NUM>. The processing device <NUM> calculates the surface area or the diameter of the weld portion <NUM> by using the stored distances and the number of pixels of the first region R1. For example, the processing device <NUM> calculates the major diameter and the minor diameter of the weld portion <NUM> as the diameter. The processing device <NUM> may calculate the average of the major diameter and the minor diameter. The processing device <NUM> may calculate the equivalent circle diameter of the first region R1 as the diameter of the weld portion <NUM>. The equivalent circle diameter of the first region R1 is obtained by calculating the diameter of an imaginary circle that has the surface area of the first region R1. The processing device <NUM> determines the goodness of the weld of the welding object by comparing any of the calculated values to a preset threshold.

The first region R1 may include only a cluster of white spots, or may include a portion of the black spots. For example, the processing device <NUM> sets a cluster of white spots and the black spots surrounded with the cluster of white spots as the first region R1. When multiple clusters of white spots exist, the processing device <NUM> sets the clusters of white spots and the black spots positioned between the clusters of white spots as the first region R1.

There are cases where the upper surface 13a and the lower surface 13b of the weld portion <NUM> are tilted with respect to the upper surface 11a of the metal plate <NUM>. This is due to the weld portion <NUM> including the solidified portion <NUM>, shape deformation in the welding process, etc. In such a case, it is desirable for the ultrasonic waves US to be transmitted along a direction that is, on average, perpendicular to the upper surface 13a or the lower surface 13b. Thereby, the ultrasonic waves can be more intensely reflected at the upper surface 13a and the lower surface 13b; and the accuracy of the inspection can be increased.

In the second determination, the appropriateness of the result of the first determination is determined. Namely, the determination result of joint or non-joint at the points performed by the first determination is determined to be appropriate or not. To determine the appropriateness of the result of the first determination, the processing device <NUM> calculates the circularness of the first region R1 set based on the result of the first determination. The roundness, the circularity, or the ellipticity can be used as the circularness.

The roundness is calculated by the following method. A circle that inscribes the outer edge of the first region and another circle that circumscribes the outer edge of the first region are set. The centers of the two circles exist at the same position. The two circles are set to reduce the spacing between the two circles. The radius difference of the two circles corresponds to the roundness. The method for setting the center of the circles is arbitrary. For example, the following four methods are used. In the first method, the center of an approximate circle of the least squares method is used. In the second method, the center of the maximum circle inscribing the outer edge is used. In the third method, the center of the minimum circle circumscribing the outer edge is used. In the fourth method, the center of the inscribed circle and the circumscribed circle at which the radius difference is a minimum is used. The roundness can be calculated in accordance with JIS B <NUM> (<NUM>). JIS B <NUM> (<NUM>) corresponds to ISO <NUM> (<NUM>).

The circularity is represented by 4nA/L<NUM> using a surface area A of the first region and a length L of the outer perimeter of the first region. The ellipticity is represented by the ratio of the major diameter to the minor diameter. For example, the major diameter is the longest line segment obtained by connecting any two points on the outer edge of the first region R1. The minor diameter is the length of a line segment that passes through the center of the major diameter and is perpendicular to the major diameter.

The ratio of a diameter r2 of the first region to an equivalent circle diameter r1 of the first region R1 may be used as the circularness. For example, the average value of the major diameter and the minor diameter is used as the diameter r2. The average value of lengths of the first region R1 in multiple directions may be used as the diameter r2.

For example, the processing device <NUM> calculates the roundness, the circularity, the ellipticity, or the ratio of the diameters as a first value of the circularness. The processing device <NUM> compares the first value to a preset first threshold. The first threshold is set according to the type of circularness used. For example, when the roundness is used as the first value, the first threshold is set based on the average diameter of the actual weld portion <NUM>. When the circularity, the ellipticity, or the ratio of the diameters is used as the first value, the first value approaches <NUM> as the shape of the first region approaches a circle. For example, a value that is greater than <NUM> and less than <NUM> is set as the first threshold.

When the first value decreases as the first region becomes circle-like, the processing device <NUM> determines that the result of the first determination is appropriate when the first value is less than the first threshold. For example, when the result of the first determination is determined to be appropriate, the processing device <NUM> performs the following first operation. In the first operation, the processing device <NUM> employs the result of the first determination. For example, the processing device <NUM> employs data derived based on the result of the first determination as the inspection result of the welding object. For example, the data includes at least one of the surface area or the diameter of the weld portion <NUM>. The data may include the goodness of the weld determined based on the surface area or the diameter of the weld portion <NUM>. The data may be derived between the first determination and the second determination or may be derived after the second determination. The processing device <NUM> may derive the data based on the result of the first determination only when the result of the first determination is determined to be appropriate. In the first operation, the processing device <NUM> may output at least one of an image of the result of the first determination, the surface area of the weld portion <NUM>, the diameter of the weld portion <NUM>, or the determination result of the goodness of the weld to the memory device <NUM> or the display device <NUM>.

When the first value is not less than the first threshold, the processing device <NUM> determines that the result of the first determination is inappropriate. For example, when the result of the first determination is determined to be inappropriate, the processing device <NUM> performs the following second operation. In the second operation, the processing device <NUM> does not employ the result of the first determination. For example, when the data such as the surface area of the weld portion <NUM>, the diameter of the weld portion <NUM>, the determination result of the goodness of the weld, or the like is derived between the first determination and the second determination, the processing device <NUM> does not employ such data as the inspection result of the welding object. In the second operation, the processing device <NUM> may output the determination result that the result of the first determination is inappropriate to the memory device <NUM> or the display device <NUM>. In the second operation, the processing device <NUM> may prompt the user to re-probe the weld portion <NUM>. When the result of the first determination is determined to be inappropriate by the processing device <NUM>, the detector <NUM> may automatically re-probe the weld portion <NUM>.

<FIG> is a bubble chart illustrating a relationship of the roundness, the ellipticity, and a test statistic.

Here, an example of performing the second determination by using the ellipticity and the roundness will be described. For example, the threshold for the circularness is statistically set using a test statistic. In <FIG>, the horizontal axis is the ellipticity. The vertical axis is the roundness. The sizes of the circles (the bubbles) illustrate the test statistic.

For example, the test statistic is calculated based on the Grubbs test. In the Grubbs test, a test statistic G is calculated by G = (r - x)/σ using the diameter r, the average value x, and the variance σ of the weld portion <NUM> calculated based on the detection result. The average value x and the variance σ are calculated based on previous inspection results. An inspection result related to another welding object welded using the same conditions as the welding object to be inspected is used to calculate the average value x and the variance σ.

The diameter r of the weld portion <NUM> is determined to be an outlier when the test statistic G is greater than <NUM>. For example, the processing device <NUM> calculates the relationship of the roundness, the ellipticity, and the test statistic for previous inspection results. The processing device <NUM> determines the value of the roundness and the value of the ellipticity that correspond to a test statistic G of <NUM> based on the calculated relationship. For example, in the example of <FIG>, a threshold of <NUM> is set for the roundness; and a threshold of <NUM> is set for the ellipticity. In the example of <FIG>, the test statistic G for <NUM>% is not more than <NUM> when the roundness is less than <NUM> and the ellipticity is less than <NUM>. The test statistic G for <NUM>% is greater than <NUM> when the roundness is not less than <NUM> or the ellipticity is not less than <NUM>.

<FIG> is a flowchart illustrating the flow of an inspection using the processing system according to the embodiment.

The user causes the tip of the detector <NUM> to contact the weld portion <NUM>. The user probes using the detector <NUM> (step S1). For example, a button for performing the probe is provided in the detector <NUM>. The user can probe using the detector <NUM> by operating the button. Or, the user may probe using the detector <NUM> via a user interface displayed by the display device <NUM>. The detector <NUM> transmits the detection result of the reflected waves obtained by the probing to the processing device <NUM>.

When receiving the detection result, the processing device <NUM> performs the first determination of determining the joint and the non-joint at multiple points of the welding object (step S2). The processing device <NUM> performs the second determination of determining the appropriateness of the result of the first determination (step S3). When the result of the first determination is determined to be appropriate, the processing device <NUM> performs the first operation (step S4). When the result of the first determination is determined to be inappropriate, the processing device <NUM> performs the second operation (step S5).

Effects of the embodiment will now be described.

For example, when inspecting a welding object, there is a method of determining the joint and the non-joint at multiple points of the welding object and determining the goodness of the weld based on the surface area of the first region R1. Or, there is a method of calculating the surface area or the diameter of the weld portion <NUM> based on the surface area or the diameter of the first region R1 and determining the goodness of the weld based on the surface area or the diameter of the weld portion <NUM>. According to these methods, the goodness of the weld of the welding object can generally be determined with high accuracy.

Further examination of the methods described above by the inventors showed that cases exist where the determination of the goodness of the weld portion <NUM> is difficult. Specifically, it was found that cases exist where a weld portion <NUM> that is actually sufficiently welded is determined to be defective even when the tilt of the detector <NUM> is sufficiently small with respect to the weld portion <NUM> and the detector <NUM> reliably contacts the weld portion <NUM>.

<FIG> and <FIG> are schematic views showing images based on detection results of reflected waves.

Similarly to <FIG>, the images of <FIG> illustrate results of the joint being determined at multiple points of the welding object. The determination results of the joint illustrated in <FIG> are based on detection results of the same portion of the same welding object and are obtained in states in which the tilts of the detector <NUM> are sufficiently small. The inventors discovered that cases exist where the shape and size of the first region R1 greatly fluctuate between the detection results as shown in <FIG>. Although the cause of the fluctuation is not yet clear, it is considered that the fluctuation is affected by the tilt of the weld portion <NUM> with respect to the entire welding object, the material of the welding object, etc..

In the image of <FIG>, a portion of the first region R1 protrudes. In <FIG>, the entire first region R1 is curved. It would be difficult for the actual weld portion <NUM> to have the shape of the first region R1 illustrated in these images. Compared to the other images, the first region R1 is close to a circle in the image of <FIG>. Compared to the first region R1 of the other images, the first region R1 of <FIG> is closer to the shape of the actual weld portion <NUM>.

<FIG> is the same as the image illustrated in <FIG>. When the major diameter and the minor diameter of the weld portion <NUM> are calculated in the inspection, there is a possibility that a major diameter L1 and a minor diameter L2 of the first region R1 may be calculated using the protruded portions as the reference as illustrated in <FIG>. In such a case, the major diameter and the minor diameter of the weld portion <NUM> that are calculated are greater than the actual value. For the surface area as well, the surface area of the weld portion <NUM> that is calculated is greater than the actual value.

In the image illustrated in <FIG>, the size of the weld portion <NUM> shown by the first region R1 is less than the size of the actual weld portion <NUM>. There is a possibility that the major diameter and the minor diameter of the weld portion <NUM> that are calculated may be less than the actual values for such images.

When the surface area or the diameter of the weld portion <NUM> that is calculated is different from the actual value, there is a possibility that the goodness of the weld also may be erroneously determined based on the surface area or the diameter of the weld portion <NUM>. For example, when the surface area or the diameter of the weld portion <NUM> that is calculated is greater than the actual value, there is a possibility that the weld may be determined to be good even though the weld actually is defective. When the surface area or the diameter of the weld portion <NUM> that is calculated is less than the actual value, there is a possibility that the weld may be determined to be defective even though the weld actually is good. When the surface area or the diameter of the weld portion <NUM> is referred to in another process for quality control, there is a possibility that a problem may occur in the other process.

For this problem, the processing device <NUM> of the processing system <NUM> according to the embodiment performs the second determination in addition to the first determination. In the second determination, the appropriateness of the result of the first determination is determined. Namely, it is determined whether or not the determination result of the joint and the non-joint is appropriate for multiple points of the welding object. To determine the appropriateness of the result of the first determination, the processing device <NUM> calculates the circularness of the first region R1 set based on the result of the first determination.

As illustrated in <FIG>, the shape of the first region has more circularness when the size and the shape of the weld portion <NUM> shown by the first region R1 are close to the actual weld portion <NUM>. The processing device <NUM> determines the result of the first determination to be appropriate when the first region based on the result of the first determination is circle-like. The result of the first determination is determined to be inappropriate when the shape of the first region is not circle-like.

For example, more accurate data related to the welding object can be derived by employing the result of the first determination only when the result of the first determination is determined to be appropriate by the second determination. For example, more accurate data for the surface area of the weld portion <NUM>, the diameter of the weld portion <NUM>, the goodness of the weld, etc., can be obtained.

By performing the second determination, it is unnecessary for the user to determine the appropriateness of the result of the first determination based on an image such as that illustrated in <FIG>. Thereby, the appropriateness of the result of the first determination can be determined without being dependent on the knowledge and the experience of the user. Even when a user that has insufficient experience performs the inspection, only the more appropriate data can be employed as the inspection result.

The processing device <NUM> may use at least two selected from the roundness, the circularity, the ellipticity, and the ratio of the diameter. For example, the processing device <NUM> calculates one selected from the roundness, the circularity, the ellipticity, and the ratio of the diameter as the first value of the circularness. The processing device <NUM> calculates another one selected from the roundness, the circularity, the ellipticity, and the ratio of the diameter as the second value of the circularness. The processing device <NUM> performs the second determination by comparing the first value and the second value respectively to the first threshold and the second threshold that are preset. For example, the processing device <NUM> determines that the result of the first determination is appropriate only when the first region R1 is determined to be circle-like based on the relationship between the first value and the first threshold and the first region R1 is determined to be circle-like based on the relationship between the second value and the second threshold.

As illustrated in <FIG>, there is a possibility that the major diameter L1 and the minor diameter L2 of the first region R1 that are calculated may be much different from the major diameter and the minor diameter of the actual weld portion <NUM>. As a result, the minor diameter L2 of the first region R1 may be a value close to the major diameter L1. Therefore, when the ellipticity is used as the circularness, there is a possibility that the first region R1 may be determined to be circle-like even though the shape of the first region R1 is much different from a circle. Accordingly, when the ellipticity is used as the circularness, it is favorable to also use the roundness, the circularity, or the ratio of the diameter.

Based on the detection result of the reflected waves, the processing device <NUM> may estimate the range of the weld portion <NUM> and calculate the tilt with respect to the weld portion <NUM>. Here, the angle between the normal direction of the surface of the weld portion <NUM> and the direction of the detector <NUM> is called the tilt. For example, the direction of the detector <NUM> corresponds to the Z-direction that is perpendicular to the arrangement direction of the detection elements <NUM>. The tilt is zero when the detector <NUM> perpendicular contacts the surface of the weld portion <NUM>.

The tilt of the detector <NUM> with respect to the welding object or the weld portion <NUM> may affect the inspection result. For example, when the first determination is performed in a state in which the detector <NUM> is tilted with respect to the welding object, there is a possibility that a non-joint may be determined even though the actual joint is appropriately joined. It is therefore favorable for the tilt of the detector <NUM> with respect to the welding object to be set to be small before performing the first determination.

The tilt of the detector <NUM> is calculated using the detection result of the reflected waves from the weld portion <NUM>. In the first determination, it is sufficient for the joint and the non-joint to be determined for the reflected waves from at least the weld portion <NUM>. The time necessary for the processing can be reduced by reducing the calculation amount of the detection result of the reflected waves from regions other than the weld portion <NUM>. It is therefore favorable to extract a portion of the detection result including the reflected waves from the weld portion <NUM> before calculating the tilt and performing the first determination.

<FIG> is a flowchart illustrating the flow of the inspection using the processing system according to the embodiment.

The flow of an inspection when the estimation of the range and the calculation of the tilt are performed is described with reference to <FIG>. The user probes using the detector <NUM> (step S1). When the probing is performed, the processing device <NUM> determines whether or not a range that corresponds to the reflected waves from the weld portion <NUM> is estimated for the welding object that is probed (step S11). When the range is not yet estimated, the processing device <NUM> estimates the range (step S12).

For example, as illustrated in <FIG> and <FIG>, the ultrasonic wave also is reflected from surfaces other than the weld portion <NUM>. The processing device <NUM> estimates the range corresponding to the reflected waves from the weld portion <NUM> and subsequently calculates the tilt based on the reflected waves included in this range. The necessary calculation amount can be reduced thereby. The accuracy of the calculated tilt can be increased.

The processing device <NUM> calculates the tilt of the detector <NUM> based on the detection result of the reflected waves within the estimated range (step S13). It is determined whether or not the calculated tilt is within a tolerance range (step S14). The determination may be performed by the user or may be performed by the processing device <NUM>. When the processing device <NUM> performs the determination, the tolerance range may be preset by the user or may be set based on the history of previous inspection results.

For example, when performing the inspection of the weld portion <NUM>, the processing device <NUM> measures the diameter of the weld portion <NUM> based on the detection result. When the tilt of the detector <NUM> is too large, the diameter of the weld portion <NUM> that is calculated is less than the actual value. The calculated diameter of the weld portion <NUM> increases as the tilt of the detector <NUM> decreases. When the tilt of the detector <NUM> is sufficiently small, the calculated diameter of the weld portion <NUM> substantially no longer changes. Such relationships between the tilt of the detector <NUM> and the diameter of the weld portion <NUM> calculated previously are stored in the memory device <NUM>. Based on the data stored in the memory device <NUM>, the processing device <NUM> determines a boundary value so that the change of the diameter of the weld portion <NUM> with respect to the change of the tilt of the detector <NUM> becomes small. The processing device <NUM> sets the size of the tolerance range based on the boundary value. For example, the processing device <NUM> sets the boundary value as the size of the tolerance range. Or, to increase the accuracy of the inspection, the processing device <NUM> may set, as the tolerance range, a smaller value that is calculated based on the boundary value.

When the tilt is not within the tolerance range, the user adjusts the tilt of the detector <NUM> (step S15). When performing step S14, the processing device <NUM> may notify the user that the tilt is not within the tolerance range. After step S15, step S1 is re-performed using the tilt after the adjustment. When the tilt is within the tolerance range, the first determination is performed (step S2). In the first determination, it is favorable for the joint or the non-joint to be determined at points in the X-Y plane within the range estimated in step S12. After step S2, steps S3 to S5 are performed similarly to the flowchart illustrated in <FIG>.

An example of specific processing of the estimation of the range, the calculation of the tilt, and the inspection will now be described.

The estimation of the range will now be described in detail with reference to <FIG>.

For example, the detection result of the reflected waves is illustrated two-dimensionally in <FIG>. The detection result of the reflected waves may be illustrated three-dimensionally. For example, multiple voxels are set for the member <NUM>. Coordinates in the X-direction, the Y-direction, and the Z-direction are set for each voxel. A reflected wave intensity is associated with each voxel based on the detection result of the reflected waves. The processing device <NUM> estimates a range (a group of voxels) corresponding to the weld portion <NUM> for the multiple voxels. The number of voxels and the size of each voxel that are set may be automatically determined or may be set by the user via the user interface of the display device <NUM>.

<FIG> are graphs illustrating the intensity distribution of the reflected waves in the Z-direction in one cross section.

<FIG> is a graph illustrating the intensity distribution of the reflected waves in the Z-direction.

The processing device <NUM> generates the intensity distribution of the reflected waves in the Z-direction based on the detection result of the reflected waves. <FIG> are such examples. In <FIG>, the horizontal axis is the position in the Z-direction, and the vertical axis is the intensity of the reflected wave. <FIG> illustrates the intensity distribution of the reflected waves in the Z-direction in one X-Z cross section. <FIG> illustrates the intensity distribution of the reflected waves in the Z-direction in one Y-Z cross section. <FIG> illustrate the results in which the reflected wave intensities are converted into absolute values.

Or, the processing device <NUM> may generate the intensity distribution of the reflected waves in the Z-direction by summing the reflected wave intensities in the X-Y plane for multiple points in the Z-direction. <FIG> is such an example. In <FIG>, the horizontal axis is the position in the Z-direction, and the vertical axis is the intensity of the reflected wave. <FIG> illustrates the results of converting the reflected wave intensities into absolute values and subtracting the average value of the reflected wave intensities from the reflected wave intensity for each of the multiple points in the Z-direction.

The intensity distribution of the reflected waves in the Z-direction includes components reflected by the upper surface 13a and the lower surface 13b of the weld portion <NUM> and components reflected by the upper surface and the lower surface of other portions. The processing device <NUM> extracts only the components reflected by the upper surface 13a and the lower surface 13b of the weld portion <NUM> from the intensity distribution of the reflected waves by filtering. For example, values that correspond to integer multiples of half of the thickness in the Z-direction (the distance between the upper surface 13a and the lower surface 13b) of the weld portion <NUM> are preset. The processing device <NUM> extracts only the periodic components of the values by referring to the values.

A band-pass filter, a zero-phase filter, a low-pass filter, a high-pass filter, threshold determination of the intensity after the filtering, etc., can be used as the filtering.

<FIG> is a graph illustrating the results of filtering the intensity distribution of the reflected waves.

In <FIG>, the horizontal axis is the position in the Z-direction, and the vertical axis is the intensity of the reflected wave. In the results of the filtering as illustrated in <FIG>, only the components reflected by the upper surface and the lower surface of the weld portion are extracted.

The processing device <NUM> estimates the range of the weld portion in the Z-direction based on the extraction results. For example, the processing device <NUM> detects peaks included in the extraction results. The processing device <NUM> detects the position in the Z-direction of a first peak and the position in the Z-direction of a second peak. For example, the processing device <NUM> uses these positions as a reference to estimate a range Ra1 illustrated in <FIG> as the range of the weld portion in the Z-direction.

There are cases where the sign (positive or negative) of the reflected wave intensity from the upper surface of the weld portion and the sign of the reflected wave intensity from the lower surface of the weld portion are mutually reversed due to the structure of the weld portion, the configuration of the element array <NUM>, etc. In such a case, the processing device <NUM> may detect a peak of one of positive or negative and another peak of the other of positive or negative. The processing device <NUM> uses the positions of these peaks as references to estimate the range of the weld portion in the Z-direction. According to the processing of the reflected wave intensity, there are cases where the reflected wave intensity has only positive values or negative values. In such a case, the range of the weld portion in the Z-direction may be estimated based on the positions of the multiple peaks, may be estimated based on the positions of the peak and the bottom, or may be estimated based on the positions of multiple bottoms. In other words, the processing device <NUM> uses the reflected wave intensity after the filtering to estimate the range of the weld portion in the Z-direction based on the positions of multiple extrema.

When the intensity distribution of the reflected waves is generated for each of the X-Z cross section and the Y-Z cross section, the range in the Z-direction based on the intensity distribution in the X-Z cross section and the range in the Z-direction based on the intensity distribution in the Y-Z cross section are estimated. For example, the processing device <NUM> calculates the average, the weighted average, the weighted moving average, or the like of the multiple estimation results and estimates the calculation result to be the range of the entire weld portion in the Z-direction.

Or, the processing device <NUM> may estimate the range of the weld portion in the Z-direction based on the intensity distribution of the reflected waves for one of the X-Z cross section or the Y-Z cross section and use the estimation result as the range of the entire weld portion in the Z-direction. The processing device <NUM> may estimate the range of the weld portion in the Z-direction based on the intensity distribution of the reflected waves for a portion in the X-direction and a portion in the Y-direction and use the estimation result as the range of the entire weld portion in the Z-direction. The calculation amount necessary for the generation of the intensity distribution of the reflected waves can be reduced by such processing.

In the example of <FIG>, the position in the Z-direction of the lower limit of the range Ra1 is set to a value of a prescribed value subtracted from the position in the Z-direction of the first peak. The position in the Z-direction of the upper limit of the range Ra1 is set to a value of a prescribed value added to the position in the Z-direction of the second peak. Thereby, the second peak can be suppressed from being outside the range in the Z-direction of the weld portion at some point in the X-Y plane if the upper surface and the lower surface of the weld portion are tilted with respect to the arrangement direction of the detection elements <NUM>.

After estimating the range of the weld portion in the Z-direction, the processing device <NUM> estimates the range of the weld portion in the X-direction and the range of the weld portion in the Y-direction.

<FIG> and <FIG> are schematic views illustrating the detection result of the reflected waves.

In <FIG> and <FIG>, a region R is the entire region in which the detection result of the reflected waves is obtained by the element array <NUM>. One cross section of the region R includes the components of the reflected waves of the upper surface and the lower surface of the weld portion and the components of the reflected waves of the upper surface and the lower surface of the other portions.

The processing device <NUM> generates the intensity distribution of the reflected waves in the X-Y plane for points in the Z-direction. The processing device <NUM> may generate the intensity distribution within a preset range in the Z-direction. The calculation amount can be reduced thereby. Or, the processing device <NUM> may generate the intensity distribution within the estimated range in the Z-direction. Thereby, the reflected wave component being outside the lower surface of the weld portion when generating the intensity distribution of the reflected waves in the X-Y plane can be suppressed while reducing the calculation amount.

<FIG> are examples of the intensity distribution of the reflected waves in the X-Y plane. <FIG> illustrates the intensity distribution of the reflected waves in the X-Y plane at the coordinate of Z = <NUM>. <FIG> illustrates the intensity distribution of the reflected waves in the X-Y plane at the coordinate of Z = <NUM>. <FIG> illustrates the intensity distribution of the reflected waves in the X-Y plane at the coordinate of Z = <NUM>. The binarized intensity of the reflected wave is schematically illustrated in <FIG>, <FIG>, and <FIG>.

The processing device <NUM> calculates the centroid position of the intensity distribution of the reflected waves in the X-Y plane for the points in the Z-direction. Here, the centroid position of the intensity distribution is obtained by calculating the centroid position of an image of the intensity distribution. For example, as illustrated in <FIG>, the processing device <NUM> calculates centroid positions C1 to C350 of the images. <FIG> illustrates the results of a line segment Li2 connecting all of the centroid positions from Z = <NUM> to Z = <NUM>.

The processing device <NUM> averages the centroid positions from Z = <NUM> to Z = <NUM>. The average position of the centroids in the X-direction and the average position of the centroids in the Y-direction are obtained thereby. In <FIG>, an average position AP illustrates the average position of the centroids in the X-direction and the average position of the centroids in the Y-direction. The processing device <NUM> uses prescribed ranges in the X-direction and the Y-direction with the average position AP at the center as a range Ra2 of the weld portion in the X-direction and a range Ra3 of the weld portion in the Y-direction.

For example, a value V that indicates the diameter of the detector <NUM> (the element array <NUM>) is preset to estimate the range Ra2 and the range Ra3. The processing device <NUM> uses AP - V/<NUM> to AP + V/<NUM> in the X-direction and the Y-direction respectively as the range Ra2 and the range Ra3. In such a case, the estimated range in the X-Y plane is quadrilateral. The estimated range is not limited to the example; the estimated range in the X-Y plane may have a five-or-higher-sided polygonal shape, a circular shape, etc. The shape of the estimated range in the X-Y plane is modifiable as appropriate according to the shape of the weld portion.

The range Ra2 and the range Ra3 may be determined using another value based on the value V. Instead of the value indicating the diameter of the detector <NUM>, a value that indicates the average diameter of the weld portion may be preset. This is because the diameter of the weld portion corresponds to the diameter of the detector <NUM>. The value that indicates the diameter of the weld portion can be considered to be a value that substantially indicates the diameter of the detector <NUM>.

The range Ra1 in the Z-direction, the range Ra2 in the X-direction, and the range Ra3 in the Y-direction of the weld portion are estimated by the processing described above. After the ranges are estimated, step S12 illustrated in <FIG> is performed based on the detection result of the reflected waves in the estimated ranges.

<FIG> is a flowchart illustrating the flow of the estimation of the range of the processing system according to the embodiment.

The processing device <NUM> generates the intensity distribution of the reflected waves in the Z-direction based on the detection result of the reflected waves by the detector <NUM> (step S121). The processing device <NUM> filters the intensity distribution based on a value of the thickness of the weld portion (step S122). Thereby, only the reflected wave components of the weld portion <NUM> are extracted from the intensity distribution. Based on the extraction results, the processing device <NUM> estimates the range of the weld portion in the Z-direction (step S123). The processing device <NUM> calculates the centroid position of the reflected wave intensity in the X-Y plane for points in the Z-direction (step S124). The processing device <NUM> calculates the average position by averaging the multiple calculated centroid positions (step S125). Based on the average position and the diameter of the detector <NUM>, the processing device <NUM> estimates the range in each of the X-direction and the Y-direction (step S126).

The estimation of the range in the Z-direction may be performed after estimating the ranges in the X-direction and the Y-direction. For example, steps S121 to S123 may be performed after steps S124 to S126 in the flowchart illustrated in <FIG>. In such a case, the processing device <NUM> may calculate the intensity distribution of the reflected waves in the Z-direction within the estimated ranges in the X-direction and the Y-direction. The calculation amount can be reduced thereby.

<FIG> is an image illustrating a detection result of the reflected waves.

In <FIG>, whiter colors show that the intensity of the reflected wave is greater at that point. The processing device <NUM> performs the operation illustrated in <FIG> for the detection result illustrated in <FIG>. As a result, a range Ra is estimated.

One specific example of a method for calculating the tilt in the range Ra will now be described.

<FIG> is a drawing for describing the processing according to the processing system according to the embodiment.

<FIG> and <FIG> are examples of images obtained by the processing system according to the embodiment.

<FIG> is three-dimensional volume data depicted based on the detection result of the reflected waves. <FIG> illustrates the surface of the weld portion <NUM> in the volume data illustrated in <FIG>. <FIG> illustrates the Y-Z cross section at the weld portion <NUM> vicinity in the volume data illustrated in <FIG>. <FIG> illustrates the X-Z cross section at the weld portion <NUM> vicinity in the volume data illustrated in <FIG>. In <FIG>, the upper side is the surface of the weld portion; and the data downward in the depth direction is shown. The portions at which the luminance is high are portions at which the reflection intensity of the ultrasonic wave is large. The ultrasonic wave is intensely reflected by the bottom surface of the weld portion <NUM>, a surface between the members not joined to each other, etc..

The tilt of the detector <NUM> corresponds to the angle between a direction 13d perpendicular to the weld portion <NUM> and a direction 130a of the detector <NUM> illustrated in <FIG>. This angle is expressed as an angle θx around the X-direction and an angle θy around the Y-direction. The direction 130a of the detector <NUM> is perpendicular to the arrangement direction of the detection elements <NUM>.

The angle θx is calculated based on the detection result in the Y-Z cross section as illustrated in <FIG>. The angle θy is calculated based on the detection result in the X-Z cross section as illustrated in <FIG>. The processing device <NUM> calculates the average of the three-dimensional luminance gradients in the cross sections as the angles θx and θy. The processing device <NUM> stores the calculated angles θx and θy in the memory device <NUM> as the tilt of the detector <NUM>. The processing device <NUM> may cause the display device <NUM> to display the calculated tilt.

By calculating the tilt of the detector <NUM> and by reducing the tilt, it can be determined with higher accuracy whether or not the points are joined in the first determination. The accuracy of the data based on the result of the first determination can be increased. By estimating the range in which the calculation of the tilt and the first determination are performed, the calculation amount necessary for the processing can be reduced.

The inspection of the weld portion described above may be automatically performed by a robot.

<FIG> is a schematic view illustrating a configuration of a processing system according to a modification of the embodiment.

<FIG> is a perspective view illustrating a portion of the processing system according to the modification of the embodiment.

The processing system 100a illustrated in <FIG> includes the processing device <NUM> and a robot <NUM>. The robot <NUM> includes the detector <NUM>, an imaging device <NUM>, a coating device <NUM>, an arm <NUM>, and a control device <NUM>.

The imaging device <NUM> acquires an image by imaging the welded members. The imaging device <NUM> extracts a weld mark from the image and detects roughly the position of the weld portion <NUM>. The coating device <NUM> coats a couplant onto the upper surface of the weld portion <NUM>.

The detector <NUM>, the imaging device <NUM>, and the coating device <NUM> are located at the distal end of the arm <NUM> as illustrated in <FIG>. The arm <NUM> is, for example, an articulated robot. The detector <NUM>, the imaging device <NUM>, and the coating device <NUM> can be displaced by driving the arm <NUM>. The control device <NUM> controls the operations of the components (the detector <NUM>, the imaging device <NUM>, the coating device <NUM>, and the arm <NUM>) of the robot <NUM>.

<FIG> is a flowchart illustrating an operation of the processing system according to the modification of the embodiment.

The processing device <NUM> transmits the coordinates of the weld portion <NUM> stored in the memory device <NUM> to the control device <NUM>. The control device <NUM> moves the distal end of the arm toward the received coordinates by driving the arm <NUM> (step S21). When the detector <NUM> is moved to the vicinity of the received coordinates, the imaging device <NUM> images the member <NUM>; and the detailed position of the weld portion <NUM> is detected using the acquired image (step S22). The control device <NUM> moves the coating device <NUM> to the vicinity of the detected position by driving the arm <NUM> (step S23). The coating device <NUM> coats the couplant onto the weld portion <NUM> (step S24). The control device <NUM> drives the arm <NUM> and moves the detector <NUM> so that the tip of the detector <NUM> contacts the weld portion <NUM> coated with the couplant (step S25). Thereafter, S1 to S5 and S11 to S15 are performed similarly to the flowchart illustrated in <FIG>.

The probing of step S2 may be re-performed in the second operation of step S5. For example, when the result of the first determination is determined to be inappropriate in step S3, the processing device <NUM> transmits the determination result to the control device <NUM>. When the determination result is received, the control device <NUM> re-performs the probe using the detector <NUM>.

At this time, the control device <NUM> may set the tilt of the detector <NUM> with respect to the welding object to the same value as the tilt of the directly-previous probe. Even when the tilt of the detector <NUM> has the same value as the directly-previous tilt, there is a possibility that the detection result of the reflected waves may be different from the directly-previous detection result. By setting the tilt of the detector <NUM> to the same value as the directly-previous tilt, the tilt is maintained within the tolerance range.

Or, the control device <NUM> may set the tilt of the detector <NUM> with respect to the welding object to a value that is different from the tilt of the directly-previous probe. In such a case, it is favorable for the change amount of the tilt to be less than the difference between the directly-previous tilt and the critical value of the tolerance range. Even when the tilt of the detector <NUM> is changed, the tilt after the change being outside the tolerance range can be suppressed thereby. By changing the tilt of the detector <NUM>, the likelihood of obtaining a detection result that is different from the directly-previous detection result of the reflected waves increases.

When the tilt of the detector <NUM> is set to a value that is different from the tilt of the directly-previous probe, the control device <NUM> may set the tilt of the detector <NUM> to be outside the tolerance range. Thereby, the tilt of the detector <NUM> is set to a value that is much different from the tilt of the directly-previous probe. As a result, the likelihood of obtaining a detection result that is much different from the directly-previous probe increases. By re-adjusting the tilt of the detector <NUM> based on the detection result that is much different from the directly-previous probe, there is a possibility that the detector <NUM> can be controlled to a state in which a more appropriate detection result is obtained.

The control device <NUM> may re-perform step S22 or S24. In other words, the control device <NUM> re-detects the position of the weld portion <NUM>. There is a possibility that a more accurate position of the weld portion <NUM> may be detected thereby, and a more appropriate result of the first determination may be obtained. Or, the control device <NUM> re-coats the couplant onto the weld portion <NUM>. For example, if the couplant is insufficiently filled between the weld portion <NUM> and the detector <NUM> in the directly-previous probe, there is a possibility that a more appropriate result of the first determination may be obtained by re-coating the couplant. After performing step S22 or S24, the subsequent steps are re-performed.

By performing the second determination in the processing system 100a, more accurate data related to the welding object can be obtained. For example, when the surface area or the diameter of the weld portion <NUM> is calculated based on the result of the first determination, a more accurate value can be obtained by employing a value based on the result of the first determination determined to be appropriate.

<FIG> is a block diagram illustrating a hardware configuration of the system.

For example, the processing device <NUM> of the processing system <NUM> according to the embodiment is a computer and includes ROM (Read Only Memory) <NUM>, RAM (Random Access Memory) <NUM>, a CPU (Central Processing Unit) <NUM>, and a HDD (Hard Disk Drive) <NUM>.

The ROM <NUM> stores programs controlling the operations of the computer. The ROM <NUM> stores programs necessary for causing the computer to realize the processing described above.

The RAM <NUM> functions as a memory region where the programs stored in the ROM <NUM> are loaded. The CPU <NUM> includes a processing circuit. The CPU <NUM> reads a control program stored in the ROM <NUM> and controls the operation of the computer according to the control program. The CPU <NUM> loads various data obtained by the operation of the computer into the RAM <NUM>. The HDD <NUM> stores data necessary for reading and/or data obtained in the reading process. For example, the HDD <NUM> functions as the memory device <NUM> illustrated in <FIG>.

Instead of the HDD <NUM>, the processing device <NUM> may include an eMMC (embedded Multi Media Card), a SSD (Solid State Drive), a SSHD (Solid State Hybrid Drive), etc..

The input device <NUM> includes at least one of a mouse, a keyboard, or a touchpad. The display device <NUM> includes at least one of a monitor or a projector. A device such as a touch panel that functions as both the input device <NUM> and the display device <NUM> may be used.

The hardware configuration illustrated in <FIG> is applicable to the control device <NUM> as well. Or, one computer illustrated in <FIG> may function as the processing device <NUM> and the control device <NUM>. Or, the function of the processing device <NUM> or the control device <NUM> may be realized by the collaboration of multiple computers.

A case is described in the examples described above where the average shape of the weld portion <NUM> is circular. The second determination described above is applicable even when the shape of the weld portion <NUM> is not a circle. For example, the processing device <NUM> extracts the outer edge of the first region R1 after setting the first region R1 based on the result of the first determination. The processing device <NUM> may determine the appropriateness of the result of the first determination based on the similarity of the outer edge of the first region R1 with a preset shape. For example, the processing device <NUM> calculates the similarity between an image of the outer edge of the first region R1 and an image that includes the preset shape. The similarity is calculated based on feature points of the images, etc. The processing device <NUM> determines the appropriateness of the result of the first determination by comparing the similarity to a preset threshold.

By using the processing system and the processing method according to embodiments described above, more accurate data related to the welding object can be obtained. Similar effects can be obtained by using a program for causing a computer to operate as the processing system.

The processing of the various data described above may be recorded, as a program that can be executed by a computer, in a magnetic disk (a flexible disk, a hard disk, etc.), an optical disk (CD-ROM, CD-R, CD-RW, DVD-ROM, DVD±R, DVD±RW, etc.), a non-transitory tangible recording medium (a non-transitory computer-readable storage medium) such as semiconductor memory, etc..

For example, the data that is recorded in the recording medium can be read by a computer (or an embedded system). The recording format (the storage format) of the recording medium is arbitrary. For example, the computer reads the program from the recording medium and causes the CPU to execute the instructions recited in the program based on the program. In the computer, the acquisition (or the reading) of the program may be performed via a network.

Claim 1:
A processing system (<NUM>), comprising:
a detector (<NUM>) including a plurality of detection elements (<NUM>) arranged in a first direction and a second direction, the first direction and the second direction crossing each other, the detector (<NUM>) being configured to perform a probe that includes transmitting an ultrasonic wave (US) toward a welding object and detecting a reflected wave (RW); and
a processing device (<NUM>) configured to receive
a detection result of the reflected wave (RW) from the detector (<NUM>), perform
a first determination of determining a joint and a non-joint at a plurality of points along the first and second directions of the welding object based on the detection result, calculate
a first value and a second value as a circularness, the first value being of one selected from a roundness, a circularity, an ellipticity, or a ratio of a diameter of the first region (R1) to an equivalent circle diameter of the first region (R1), the second value being of another one selected from the roundness, the circularity, the ellipticity, or the ratio, and perform
a second determination of comparing the first value to a first threshold and comparing the second value to a second threshold so as to determine an appropriateness of a result of the first determination, the first threshold and the second threshold being preset.