DESC:SEMI AUTOMATED SYSTEM AND METHOD FOR HARDNESS TESTING
BACKGROUND
Technical Field
[0001] Embodiments of this disclosure generally relate to hardness testing, and more particularly, to a semi-automated system for hardness testing of a component with customized tooling arrangement to measure the hardness on two sides of the component accurately with less manual efforts.
Description of the Related Art
[0002] Hardness testing is a process that enables users to evaluate a material’s properties including strength, ductility, and wear resistance, and to determine whether the material is suitable for a required purpose or not based on the material properties. Normally, the hardness testing is performed by pressing a specifically dimensioned and loaded object into a surface of the material, and determining the hardness by measuring a depth of indenter penetration or by measuring a size of an impression of the material.
[0003] In earlier days, a hardness testing apparatus is used to determine the hardness of a component. The hardness testing apparatus includes a load that can be applied to the surface of the component by an indenter to form a dimple on the surface of the component, and the hardness of the component is measured. Nowadays, a Brinell Hardness Testing Process is used to determine the hardness of the component. But, the Brinell Hardness Testing process requires more manual efforts for grinding, indentation, and measurement of hardness based on the indentation.
[0004] Existing hardness testing process is suitable only for holding and testing one type of component with a certain size, but may not be capable of detecting hardness of different sizes or types of the component. Further, the existing hardness testing process requires manual replacing of one or more units of a testing machine to expand or retract to measure hardness of the different sizes or types of the component. Further, the existing hardness testing process consumes more time while placing the component at a right place whenever measuring the hardness on different sides of the component. The operator should place the component at an accurate position else the calculation or the hardness measurement of the component will be a wrong value, which results in improper usage of the component in the required purpose.
[0005] Accordingly, there remains a need to address aforementioned technical draw backs in existing known technologies in hardness testing.
SUMMARY
[0006] In view of foregoing an embodiment herein provides a semi-automated system and a method for measuring hardness of a component.
[0007] In a first aspect, a semi-automated system for measuring hardness of a component is provided. The semi-automated system includes (i) a handling station that includes a plurality of tools to handle the component, (ii) a fixture that is configured to clamp the component, and (iii) a measuring station. The plurality of tools includes (i) at least one gripper for holding the component at a bore of the component after an operator loads the component to the at least one gripper with a measuring surface that faces upward direction, (ii) a rotary actuator for rotating the component to a predefined angle, and (iii) a track for guiding the handling station, between a starting position and a measuring position. The measuring surface includes at least one of a first measuring surface or a second measuring surface. The measuring surface of the component is indented before loading to the at least one gripper. The measuring station includes one or more cameras that are configured to acquire at least one indentation image of the component; and a control unit that is configured to (i) enable the handling station to move from the starting position to the measuring station along the track in a forward direction after receiving a cycle start signal which depicts that the component is loaded to the at least one gripper, (ii) clamp, using the fixture, the component at a first side while the at least one gripper holding the component at the bore of the component, (iii) acquire, using the one or more cameras, at least one indentation image of the first measuring surface of the component, wherein the first measuring surface is parallel to the one or more cameras; (iv) enable the handling station to move from the measuring station to the starting position in a backward direction after de-clamping the component at the first side while the at least one gripper holding the component at the bore, (v) rotate, using the rotary actuator, the component to the predefined angle after reaching the starting position, wherein the second measuring surface of the component faces the upward direction after rotating the component to the predefined angle, (vi) enable the handling station to move from the starting position to the measuring station along the track, (vii) acquire, using the one or more cameras, at least one indentation image of the second measuring surface of the component, wherein the fixture clamp the component at a second side while the at least one gripper holding the component at the bore of the component and (viii) measure, using the image processing unit, hardness of the first measuring surface and the second measuring surface by processing the at least one indentation image of the first measuring surface and the second measuring surface of the component. The second measuring surface is parallel to the one or more cameras.
[0008] In some embodiments, the control unit is configured to log and display one or more hardness values of the component in a user device.
[0009] In some embodiments, the plurality of tools includes (i) one or morecomponent stoppers that is configured to locate the component in a fixed position, (ii) one or more preventers that is configured to prevent the component from being placed in a wrong position, that enables the component to be placed only in a desired position, and (iii) a compensation unit that is configured to adjust the measuring surface of the component parallel to the one or more cameras.
[0010] In some embodiments, the track includes (i) a linear motion rail that is configured to enable at least one of a linear forward motion or a linear backward motion of the handling station in the track, (ii) a handling station cylinder that is configured to move the handling station between the starting position and the measuring station, and (iii) a handling station stopper that is configured to stop the handling station at different forward positions in the track.
[0011] In some embodiments, the measuring station includes a lighting system that is positioned below the one or more cameras for illuminating the measuring surface of the component while measuring the hardness of the component, (ii) a lens that is mounted on the one or more cameras to magnify the measuring surface of the component, (iii) a mount that is configured to couple with the one or more cameras, (iv) a camera holding arm that is configured to hold the mount along with the one or more cameras, (v) a measuring camera stopper that is configured to stop the mount along with the one or more cameras at a top level, and (vi) a measuring camera cylinder that is configured to move the one or more camerasbetween a top position or a bottom position.
[0012] In some embodiments, the lighting system includes a height adjustment unit for adjusting the height of the lighting system for illuminating the component.
[0013] In some embodiments, the mount includes (i) a height adjustment unit to adjust the height of the one or more cameras to acquire the at least one of indentation image of the component, and (ii) a tilt adjust unit to tilt the one or more cameras to one or more positions to acquire the at least one of indentation image of the component to be measured.
[0014] In some embodiments, the fixture includes an arm locating plate that includes an arm clamping cylinder, a clamp, and a V block for arranging the measuring face of the component parallel to the one or more cameras, (ii) a top level fixture stopper that is configured to stop the fixture at a top level, (iii) a plate locating cylinder that is configured to position the arm locating plate up before clamping the component and down after de-clamping the component, and (iv) a bottom level fixture stopper that is configured to stop the fixture at a bottom level. The arm clamping cylinder is configured to clamp or de-clamp the component to a fixture surface using the clamp.
[0015] In a second aspect, a semi-automated method for measuring hardness of a component is provided. The method includes (i) loading, by an operator, the component to at least one gripper of a handling station with a measuring surface that faces upward direction, the handling station includes a least one gripper, a rotary actuator, and a track, (ii) enabling, by a control unit of the measuring station, the handling station to move towards a measuring station from the starting position in a forward direction along the track after receiving a cycle start signal which depicts that the component is loaded to the at least one gripper, (iii) clamping, using a fixture, the component at a first side while the at least one gripper holding the component at a bore of the component, (iv) acquiring, using one or more cameras of the measuring station, at least one indentation image of a first measuring surface of the component, the first measuring surface is parallel to the one or more cameras, (v) enabling the handling station to move from the measuring station to the starting position in a backward direction after de-clamping the component, at the first side while the at least one gripper holding the component at the bore, (vi) rotating, using the rotary actuator, the component to the predefined angle after reaching the starting position, a second measuring surface of the component faces the upward direction after rotating the component to the predefined angle, (vii) enabling the handling station to move from the starting position to the measuring station along the track, wherein the fixture clamps the component at a second side while the at least one gripper holding the component at the bore of the component, (viii) acquiring, using the one or more cameras, at least one indentation image of the second measuring surface of the component, wherein the second measuring surface is parallel to the one or more cameras, and (ix) measuring, using an image processing unit, hardness of the first measuring surface and the second measuring surface by processing the at least one indentation image of the first measuring surface and the second measuring surface of the component.The measuring surface includes at least one of the first measuring surface or the second measuring surface.The measuring surface of the component is indented before placing to the at least one gripper. The handling station being moveable along the track between a starting position and a measuring station.
[0016] In some embodiments, the semi-automated method includes logging and displaying one or more hardness values of the component in a user device.
[0017] The semi-automated system and method perform measuring of hardness of the components with less manual effort. Further, the semi-automated system and method may handle one or more different measuring surfaces of the component to the measuring process using the tooling arrangement. The tooling arrangement may be customized to accommodate the different components with different sizes. The one or more components of the measuring station may be customized to measure hardness of different components.
[0018] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The embodiments herein will be better understood from the following detailed description with reference to the drawings, in which:
[0020] FIG. 1 illustrates a block diagram of a semi-automated system for measuring hardness of a component according to some embodiments herein;
[0021] FIG. 2 illustrates a block diagram of the semi-automated system according to some embodiments herein;
[0022] FIG. 3A illustrates an exemplary view of a handling station of the semi-automated system of FIG. 1 according to some embodiments herein;
[0023] FIG. 3B illustrates an exemplary view of a fixture of the semi-automated system of FIG. 1 according to some embodiments herein;
[0024] FIG. 3C illustrates an exemplary view of a measuring station of the semi-automated system of FIG. 1 according to some embodiments herein;
[0025] FIGS. 4A-4E illustrate exemplary views of one or more operating positions of the semi-automated system of FIG. 1 while measuring the hardness value of the component according to some embodiments herein;
[0026] FIGS. 5A-5B illustrate an exemplary perspective view and an exemplary top view of the semi-automated system of FIG. 1 according to some embodiments herein;
[0027] FIGS. 6A-6Billustrate a left perspective view and a right perspective view of a handling station of the semi-automated handling system of FIG. 1 according to some embodiments herein;
[0028] FIG. 6C illustrates a handling station of the semi-automated handling system of FIG. 1 with one or more block rails according to some embodiments herein;
[0029] FIG. 6D illustrates one or more components of a fixture of the semi-automated handling system of FIG. 1 according to some embodiments herein;
[0030] FIG. 6E illustrates a measuring station of the semi-automated handling system of FIG. 1 according to some embodiments herein;
[0031] FIG. 6F illustrates a camera holder in a measuring station of the semi-automated handling system of FIG. 1 according to some embodiments herein;
[0032] FIG. 6G illustrates one or more components of the tooling assembly of the handling station according to some embodiments herein;
[0033] FIG. 6H illustrates a perspective view of a track for the handling station according to some embodiments herein;
[0034] FIGS. 7A-7Billustrate flow diagrams of a method for measuring hardness of the component using the semi-automated handling system of FIG. 1 according to some embodiments herein; and
[0035] FIG. 8 is a schematic diagram of computer architecture of an image processing system with a control unit or one or more cameras, in accordance with the embodiments herein.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0036] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0037] As mentioned, there remains a need for a semi-automated handling system for hardness testing of a component with a customized tooling arrangement to measure the hardness on both sides of the component accurately with less manual effort. Referring now to the drawings, and more particularly to FIGS. 1 through 8, where similar reference characters denote corresponding features consistently throughout the figures, there are shown preferred embodiments.
[0038] In the description of the present disclosure, the term “first side” is to be understood as meaning a supporting part or arm in the component which is hold or clamped by the fixture. The term “second side” is to be understood as meaning a supporting part or arm in the component which is hold or clamped by the fixture. The first side and the second side are two different supporting parts or arms. For brevity, the first side and the second are two different positions in the component. While the gripper holding the component at a bore of the component which is located at the center of the component, the fixture holds the component at any one side side (first side or second side).
[0039] In the description of the present disclosure, it should be noted that, the directions or positional relationships indicated by the terms, “front”, “bottom”, “left”, “right”, “back”, “top”, ‘forward”, “backward” and the like are based on the orientation or position relationships shown in the drawings, which is only for the convenience of describing the present application and simplifying the description, and does not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, so it cannot be understood as limiting the present disclosure. The meaning of “one or more” means at least one or more than one, unless otherwise specifically defined.
[0040] FIG. 1 illustrates a block diagram of a semi-automated system 100 for measuring hardness of a component according to some embodiments herein. The semi-automated system 100 includes a handling station 102, a fixture 104, and a measuring station 106. The handling station 102 is configured to handle the component. The component may be an automotive component. The automotive component may be a steering knuckle. The component may be placed by an operator. The handling station 102 includes a gripper, a compensation unit, a rotary actuator, and a track, to handle the component. The operator may load the component manually to the gripper. The gripper holds the component at a bore of the component after the operator loads the component to the gripper with a measuring surface that faces upward direction. The measuring surface includes at least one of a first measuring surface or a second measuring surface. The measuring surface may include one or more measuring surfaces. The measuring surface of the component is indented before loading to the gripper. The fixture 104 is configured to hold the component at a first side or a second side while the gripper holding the component at the bore of the component which is located at the center of the component. The first side may be in the first measuring surface. The second side may be in the second measuring surface. In one example, the first side is TRA and the second side is SBA. The gripper holds the component in the bore which is located at the center of the component. The fixture clamps and de-clamps the first side or the second side whichever side’s indentation image is acquired respectively. The fixture 104 may include at least one of a locating block and a clamping cylinder for holding the component. The fixture 104 may hold a supporting part of the component. The fixture 104 may hold arms of the steering knuckle. The fixture 104 may be used for viewing indentation. The fixture 104 may be connected to the handling station 102. The rotary actuator is configured to rotate the component to a predefined angle. The track guides the handling station 102 between a starting position and a measuring position.
[0041] The measuring station 106 is configured to measure the hardness of the component based on indentation on the measuring surface. The measuring station 106 includes one or more cameras 108A-N, one or more camera handling stations, and a control unit 110. The measuring station 106 may include an attachment for handling the one or more cameras 108A-N. The one or more cameras 108A-N are configured to acquire one or more indentation images of the component. The one or more camera handling stations are configured to handle or operate the one or more cameras 108A-N to capture the one or more indentation images of the component. The operator may load the component to the gripper with a Tie Rod Arm(TRA) as a first measuring face that is facing upwards, and with a Strut Bracket Arm(SBA) facing downwards. The operator may load the component to the gripper with embossed letters facing upwards. Before loading the component to the gripper, a hardness testing face and butting faces of the component are ground that removes sharp edges, burrs, and provides parallel placement of the component. The handling station 102 along with the track is placed in such a way that the indentation of the component (e.g., steering knuckle arm) is located right below a field of view of one or more cameras 108A-N in the measuring station 106.
[0042] The control unit 110 is configured to initiate a cycle that enables the semi-automated system 100 for hardness testing after receiving a cycle start signal. The cycle start signal depicts that the component loaded to the gripper. The control unit 110 may include a microcontroller or a Programmable Logic Controller, PLC for initiating the cycle based on the component loaded to the gripper. When the cycle start signal is initiated or received, the control unit 110 enables the handling station 102 to move towards from a home position to the measuring station 106 for hardness measurement on the first measuring surface and retracts the handling station 102 to the home position when the indentation on the first measuring surface is measured. The home position may be a starting position. The first measuring surface may be a TRA face. The control unit 110 enables the fixture 104 to de-clamp the component from the fixture 104 while the gripper holds the component. The control unit 110 is configured to enable the rotary actuator to rotate the component to a predetermined angle of degrees. The predetermined angle of degrees may be in a range of 45 degrees to 135 degrees. In some embodiments, the component is placed in the rotating component (called as rotary actuator), which enables the component to rotate while the gripper holds the component. The control unit 110 may enable the component to rotate about 90 degrees. The control unit 110 is configured to enable the handling station 102 to move towards the measuring station 106 after rotating the component to the predetermined angle of degrees for hardness measurement on the second measuring surface, and retract the handling station 102 to the home position when the indentation of the second measuring surface is measured. The second measuring surface may be an SBA face.
[0043] The control unit 110 is configured to measure the hardness of the component with the indentation on the first measuring surface and the indentation on the second measuring surface using an image processing unit. The image processing unit may measure the indentation of the first measuring surface and second measuring surface of the component and records hardness values of the component in a database. The database may be embedded in the measuring station 106. The recorded hardness values may be viewed on a user device. The user device may be, but not limited to, a computer, a mobile phone, a laptop, a personal digital assistant, and the like. The operator may de-clamp the component using a foot pedal that releases the component from the gripper. The control unit 110 may enable the one or more camera handling stations to operate the one or more cameras 108A-N automatically to capture the one or more indentation images of the component.
[0044] The component may be de-clamped from the fixture 104 after measuring hardness on the second measuring surface. The control unit 110 is configured to turn, using the rotary actuator, the component back to its original position, that enables the component to be unloaded from the gripper. The operator may manually unload the component for placing a new component for the hardness measurement. In some embodiments, the component is de-clamped from the fixture 104 after measuring hardness on the first measuring surface that enables the component to be unloaded after the hardness measurement on the first measuring surface, when the hardness measurement on the second surface is not required by the operator. The component may be handled using a robot (or) pallet conveyor along with a gantry, that provides automatic sorting of the component.
[0045] The semi-automated system 100 may include a memory that stores instructions and a processor that executes the stored instructions for measuring the hardness of the component. In some embodiments, the semi-automated system 100 includes a control system that enables the semi-automated system 100 to measure the hardness of the component automatically without any manual efforts. The semi-automated handling system 100 may be implemented on a Brinell Hardness Testing Machine.
[0046] FIG. 2 illustrates a block diagram of the semi-automated system 100 according to some embodiments herein. The semi-automated system 100 includes a control panel 202, an image processing system 204, and a vision system 206. The control panel 202 is configured to control the cycle of the semi-automated system 100. The control panel 202 may be a Programmable Logic Controller, PLC. The control panel 202 may include accessories to act as an enclosure. The control panel 202 controls the semi-automated system 100 by initiating the cycle after the placement of the component, enabling the movement of the handling station 102 forward and backward based on any of the hardness measurement on the first measuring surface or the second measuring surface, capturing the one or more indentation images of any of the first measuring surface or the second measuring surface, and turning of the rotary actuator to rotate the component for the pre-determined angle of degrees. The indentation of the component may be determined using a Brinell Hardness Indentation Machine.
[0047] The image processing system 204 is configured to process the one or more indentation images first measuring surface or the second measuring surface, to measure the indentation that enables determination of a hardness value of the component. The image processing system 204 may measure diameter of the indentation on the first measuring surface or the second measuring surface to determine the hardness values of the component. The image processing system 204 may measure the indentation and the hardness values of the component and transmit the hardness values of the component to the user device associated with the operator. The user device may include a spreadsheet application that enables the control panel 202 to log and display the hardness values of the component for any of tracking or statistical process and control purpose. The operator may search or compare the hardness values of the component. The vision system 206 includes a camera, lens, a lighting system, and a protector for preventing external lighting for capturing the one or more indentation images of the component. The vision system 206 may enable the semi-automated system 100 to measure a diameter of the indentation that enables determination of the hardness value of the component.
[0048] In some embodiments, the indentation and the hardness value of the component enable the operator to sort the component whether the component is a correct component or a defective component based on the indentation measurement and the hardness value. The semi-automated system 100 may include a constraint-free axis in a Z-direction that facilitates any of raising or lowering of the component for measurement of the indentation. One or more stoppers are used to stop or position a tooling assembly of the handling station 102 at a top level or bottom level, thereby enabling any of raising or lowering of the component for measurement of the indentation. The semi-automated system 100 may include a pneumatic cylinder that accommodates other faces of the component for hardness testing. The pneumatic cylinder or tooling cylinder is a up cylinder or down cylinder that locates or positions a tooling assembly of the handling station 102 in any of upper position or down position, thereby accommodating different faces of the component for hardness testing.
[0049] In some embodiments, the semi-automated system 100 includes an electrical linear actuator for movement of the handling station 102, pneumatic actuators with linear encoders, or distance measuring devices for the movement of the handling station 102. In some embodiments, the semi-automated handling system 100 includes one or more grippers to load and unload one or more components.
[0050] FIG. 3A illustrates an exemplary view of the handling station 102 of the semi-automated system 100 according to some embodiments herein. FIG. 3B illustrates an exemplary view of the fixture 104 of the semi-automated system 100 according to some embodiments herein. FIG. 3C illustrates the measuring station 106 of the semi-automated system 100 according to some embodiments herein. The functions and explanations of the handling station 102, the fixture 104, and the measuring station 106 are explained above.
[0051] FIGS. 4A-E illustrate exemplary views of one or more operating positions of the semi-automated system 100 of FIG.1while measuring the hardness value of the component according to some embodiments herein. FIG. 4A illustrates an exemplary view of the semi-automated system 100 where the handling station 102 is at the home position according to some embodiments herein after loading the component to the gripper with facing the first measuring surface upward direction. The component may be a steering knuckle 400. The gripper holds the component at the bore of the component. FIG. 4B illustrates an exemplary view of the semi-automated system 100 at a first measuring position according to some embodiments herein. In the exemplary view of the FIG.4B, the component is clamped at the fixture 104 at the first measuring surface faces upward. The first measuring surface may be a Tie Rod Arm(TRA), TRA face, that is clamped at the fixture 104. The first measuring position is a TRA position. The first measuring position enables to measure the hardness of the component in the first measuring surface. For example, indentation on the first measuring surface of the component is measured to determine the hardness of the component. The TRA position enables to measure the hardness of the component in the TRA face. For example, indentation on the TRA face of the component is measured to determine the hardness of the component at TRA face.
[0052] FIG. 4C illustrates an exemplary view of the semi-automated system 100 at the home position after hardness measurement on the first measuring surface and turned 90 degrees to second measuring face according to some embodiments herein. In FIG. 4C, the handling station 102 turns or rotates the component using rotating actuator to enable the second measuring surface face upwards direction. The second measuring surface may be a Strut Bracket Arm(SBA) face. The component with an SBA position enables measurement of the indentation on the SBA face of the component. FIG. 4D illustrates an exemplary view of the semi-automated system 100 at a second measuring position according to some embodiments herein. In the exemplary view of the FIG.4D, the component is clamped at the fixture 104 at the second side of the component where the second measuring surface faces upward. The second measuring position is an SBA position. The second measuring position enables to measure the hardness of the component in the second measuring surface. For example, indentation on the second measuring surface of the component is measured to determine the hardness of the component. The SBA position enables to measure the hardness of the component in the SBA face. For example, indentation on the SBA face of the component is measured to determine the hardness of the component at SBA face. The semi-automated system 100 moves to the home position after the measurement of indentation in the second measuring surface and turns the component using the rotary actuator to enable to remove the component from handling station 102 for the next cycle. FIG. 4E illustrates an exemplary view of a tooling assembly 412 in the handing station 102. The tooling assembly 412 is configured to rotate the component in any of the TRA position or the SBA position. The handling station 102 shows a knuckle position cylinder 402 at a bottom for a right hand (RH) component. In some embodiments, a position of the knuckle position cylinder 402 can be changed for a left hand (LH) component. The knuckle position cylinder 402 moves front and back to locate the TRA face and SBA face compensating their dimensional locations. When the knuckle position cylinder 402 is mounted from front, knuckle position cylinder 402 works for the RH component. When the knuckle position cylinder 402is mounted from the back, knuckle position cylinder 402works for the LH component.
[0053] FIGS. 5A-5B illustrate an exemplary perspective view 500 and an exemplary top view 501 of the semi-automated system 100 of FIG. 1 according to some embodiments herein. The perspective view 500 and the top view 501 includes a measuring station assembly 502, a handling station assembly 504, a track 506, a foot pedal switch 508, a push button station 510, an operator 512, and a control panel 202. The operator 512 operates the semi-automated system 100. The measuring station assembly 502 is configured to house the fixture and the camera holding station. The handling station assembly 504 includes one or more toolings for gripping and rotating the component to a required position while measuring the hardness of the component. In some embodiments, the measuring station assembly 502 is an assembly for the measuring station 106, and the handling station assembly 504 is an assembly for the handling station 102. The track 506 is a way that enables the movement of the handling station assembly 504 along the track 506 between the handling station 102 and the measuring station 106. The track 506 houses the handling station assembly 504. In some embodiments, the track 506 houses a stopper and a front/back positioning cylinder of the handling station assembly 504. The foot pedal switch 508 is configured to enable clamping or de-clamping of the component to the gripper in the handling station assembly 502. The foot pedal switch 508 is configured to clamp or de-clamp the component in the handling station 102. For example, the operator loads the component to the gripper by pressing the foot pedal switch 508. Similarly, the operator releases the component from the gripper by pressing the foot pedal switch again 508. The push button station 510 houses one or more push buttons for operations of the semi-automated system 100. The one or more push buttons may include a cycle start button, a cycle end button, an emergency stop button, and the like. The control panel 202 is configured to control the semi-automated handling system 100 to any of initiating the cycle start operation or initiating the cycle end operation of the semi-automated handling system 100 after receiving a cycle start signal or a cycle end signal. In some embodiments, the control panel 202 controls the semi-automated handling system 100 based on the operations from the one or more push buttons. After pressing the cycle start button, the semi-automated system 100 starts a hardness measurement process. After pressing the emergency stop button, the semi-automated system 100 stops hardness measurement process at any stage.
[0054] FIGS. 6A-Billustratea left perspective view and a right perspective view of the handling station 102 of the semi-automated handling system 100 according to some embodiments herein. The handling station 102 includes a tooling assembly 602, a tooling assembly rail 604, a pillar 606, a tooling cylinder 608, a top level stopper 610, a base plate 612, a mount 614 for locating a knuckle positioning cylinder, a block 616, and a bottom level stopper 618. The tooling assembly 602 is configured to hold the component with the measuring surface parallel to the one or more cameras 108A-N.The tooling assembly 602 is configured to rotate the component to the predefined angle that enables at least one of first measuring surface or the second measuring surface faces upward direction for measuring hardness. For example, the tooling assembly 602 is configured to rotate the component for any of the TRA face measurements or the SBA face measurements. The tooling assembly rail 604 is configured to enable precise linear motions of the tooling assembly 602. The tooling assembly rail 604 may be a linear motion rail. In some embodiments, the tooling assembly rail 604 is configured to enable any of a linear up motion or a linear down motion of the tooling assembly 602 to accommodate TRA face and SBA face compensating their dimensional locations. The pillar 606 is configured to mount the tooling assembly rail 604. The tooling cylinder 608 is configured to position the tooling assembly 602 in one or more vertical positions at one or more heights of the pillar 606 based on height and thickness of the measuring surface of the component, that enables measurement of different components with different height and thickness. In some embodiments, the tooling cylinder 608 is a up cylinder or down cylinder that locates or positions the tooling assembly 602 in any of upper position or down position in the pillar 606. The stopper 610 is configured to stop the tooling assembly 602 at a top level. In some embodiments, a position of the top level can be adjusted by the operator. The base plate 612 is configured to mount the pillar 606. The mount 614 for knuckle positioning cylinder eye end for the TRA measurements and the SBA measurements of the component. The block 616 is configured to enable precise linear motion of the tooling assembly 602 along with the pillar 606 in the tooling assembly rail 604 to position the TRA (or) SBA compensating their dimensional location. In some embodiments, the block 616 is a linear motion block. The block 616 may enable any of a front linear motion or a back linear motion of the tooling assembly 602 along with the pillar 606. The stopper 618 is configured to stop the tooling assembly 602 at a bottom level. In some embodiments, a position of the tooling assembly 602 in the bottom level can be adjusted by the operator.
[0055] FIG. 6C illustrates the handling station 102 of the semi-automated system 100 with one or more block rails 622A-B according to some embodiments herein. The handling station 102 includes a positioning cylinder 620, the one or more block rails 622A-B, a pillar stopper 624, and a manifold mount 626. The positioning cylinder 620 is configured to enable motion of the tooling assembly 602 along with the pillar 606. In some embodiments, the positioning cylinder 620 enables any of a front motion or a back motion of the tooling assembly 602 along with the pillar 606. The one or more block rails 622A-B are configured to connect with the block 616, that enables linear front motion or linear back motion of the tooling assembly 602 along with the pillar 606. The pillar stopper 624 is configured to stop the pillar 606 at a front position while the pillar 606 is in linear front motion. In some embodiments, the front position can be adjusted by the operator. In some embodiments, the handling station 102 includes a pillar stopper to stop the pillar 606 at a back position while the pillar 606 is in linear back motion, and a handling station stopper block positioning cylinder that is configured to position a handling station stopper block either at front or at the back, so that the handling station to be positioned at one or more forward positions according to different lengths of the component. For example, the handling station stopper block positioning cylinder is configured to position the handling station 102, for measuring hardness in the TRA face and SBA face, in one or more forward positions or in one or more backward positions according to the difference in length if the component. In some embodiments, the handling station 102 includes a mount for handling station front and back cylinder eye end, and the handling station stopper block at a back side of the base plate 612. The handling station stopper block may change positions of the handling station 102 on the track during handling station cylinder forward stroke. For example, when the handling station stopper block is at the forward position, it positions or locates the handling station 102 in the track at a first position for measuring indentation of TRA and similarly, when the handling station stopper block is at the back position, it positions or locates the handling station 102 in the track at a second position to measure the indentation of SBA. The manifold mount 626 is used to mount a pneumatic manifold which along with directional control valve supplies the compressed air to the positioning cylinder 620, gripper 676, compensation unit 680, and rotary actuator 684 (as shown in FIG. 6G).
[0056] FIG. 6D illustrates one or more components of the fixture 104 of the semi-automated system 100 according to some embodiments herein. The fixture 104 includes an arm clamping cylinder 628, a clamp 630, an arm locating plate 632, a camera stopper 634, a top level fixture stopper 636, an arm locating plate cylinder 638, a bottom level fixture stopper 640, and a V block 642. The arm clamping cylinder 628 is configured to any of clamp or de-clamp the component to a fixture surface using the clamp 630. In some embodiments, the arm clamping cylinder 628 clamps or de-clamps the arm of the steering knuckle to the fixture surface using the clamp 630. The arm locating plate 632 includes the V block 642, the arm clamping cylinder 628, and the clamp 630, that enables the measuring surface of the component or arm measuring face parallel to a measuring camera system that includes one or more cameras 108A-N. The V block 642 is used to locate a cylindrical component or components with circular edges. For example, both TRA and SBA includes circular edges. Accordingly, the V block 642 is used to locate the components with circular edges. The camera stopper 634 is configured to stop the measuring camera system at a bottom level. A position of the measuring camera system at the bottom level is adjusted by the operator. The top level fixture stopper 636 is configured to stop the fixture 104 at a top level. In some embodiments, a position of the fixture 104 at the top level is adjusted by the operator. The arm locating plate cylinder 638 is configured to position the arm locating plate 632 up before clamping the component and down after de-clamping the component. For example, the arm locating plate cylinder 638 is configured to position the arm locating plate 632 up before clamping the arm of the steering knuckle, and down after de-clamping the arm of the steering knuckle. The bottom level fixture stopper 640 is configured to stop the fixture 104 at a bottom level. In some embodiments, a position of the fixture 104 at the bottom level is adjusted by the operator.
[0057] FIG. 6E depicts the measuring station 106 of the semi-automated system 100 according to some embodiments herein. The measuring station 106 includes a measuring camera system 642, the arm locating plate 632, and a camera holding station 644. The measuring station 106 may include a base plate for locating the arm locating plate 632 and the camera holding station 644. In some embodiments, the measuring station 106 includes a fixture that can be interchanged based on a design of the components to be measured. The camera holding station 644 may be interchanged based on sizes of the components to be measured. In some embodiments, the measuring station 106 includes a protection for the measuring camera system 642 from external collision. In some embodiments, the measuring station 106 includes one or more cameras for code identification of embossed letters in casting.
[0058] FIG. 6F illustrates a camera holder 646 in the measuring station 106 of the semi-automated system 100 according to some embodiments herein. The camera holder 646 includes a camera holding station 648, a lighting system 650, a lens 652, a measuring camera 654, a mount 656 for the measuring camera, a camera holding arm 658, a measuring camera stopper 660, and a measuring camera cylinder 662. The camera holding station 648 is a hood or a base plate for the camera holder 646, that is connected with the measuring station 106. The lighting system 650 provides lighting while measuring using the measuring camera 654. In some embodiments, the lighting system includes a height adjustment unit for adjusting the height of the lighting system for illuminating the measuring surface of the arm of the steering knuckle or the component. The lens 652 is mounted on the measuring camera 654 to magnify the measuring surface of the component. The mount 656 for the measuring camera includes a height adjustment unit and a tilt adjustment unit. The height adjustment unit in the mount 656 adjusts the height of the measuring camera 654 to acquire one or more indentation images of the measuring surface of the component. The tilt adjustment unit in the mount 656 rotate the measuring camera 654 to acquire one or more indentation images of the measuring surface of the component. The camera holding arm 658 is configured to hold the mount 656 along with the measuring camera 654. The measuring camera stopper 660 is configured to stop the mount 656 along with the measuring camera 654 at a top level. In some embodiments, a position of the top level can be adjusted by the operator. The measuring camera cylinder 662 is configured to position the mount 656 along with the measuring camera 654 at any of a top position or a bottom position. In some embodiments, the bottom position is achieved by a stopper.
[0059] FIG. 6G illustrates one or more components of the tooling assembly 602 of the handling station 102 according to some embodiments herein. The tooling assembly 602 includes one or more component stoppers 664A-N, one or more preventers 666A-N, a tooling base plate 668, one or more tooling assembly blocks 670A-N, a mount for tooling assembly 672, a gripper mounting plate 674, a gripper 676, a finger 678, a compensation unit 680, a compensation unit mounting plate 682, and a rotary actuator 684. The one or more component stoppers 664A-N is configured to locate the component in a fixed position, with the gripper 676 and the finger 678 for holding the component. The finger 678 is configured to hold the component. In some embodiments, the one or more component stoppers 664A-N locates the steering knuckle in a fixed position. The one or more preventers 666A-N prevents the component from placing in a wrong position, that enables the component to be placed only in a required position. The compensation unit 680 is configured to adjust the measuring arm or the measuring surface parallel to the measuring camera for machining tolerance. The compensation unit mounting plate 682 is configured to mount the compensation unit 680. The rotary actuator 684 is configured to rotate the component between one or more measuring surfaces. For example, the rotary actuator 684 is configured to rotate the component between the TRA face and the SBA face, during the cycle process. The tooling base plate 668 connects the rotary actuator 684, with the handling station 102. The one or more tooling assembly blocks 670A-N enables precise linear motion of the tooling assembly 602. In some embodiments, the one or more tooling assembly blocks 670A-N provides any of a linear up motion or a linear down motion of the tooling assembly 602. The mount for tooling assembly 672 is for a tooling up/down cylinder eye end.
[0060] FIG. 6H illustrates a perspective view of a track 686 for the handling station 102 according to some embodiments herein. The track 686 includes a linear motion rail 688, a handling station cylinder 690, and a handling station stopper 692. The linear motion rail 688 is configured to enable a precise linear motion of the handling station 102 in the track 686. In some embodiments, the linear motion includes a front linear motion or a back linear motion of the handling station 102. The handling station cylinder 690 is configured to move the handling station 102 between the starting position or the home position and the measuring station 106. The handling station stopper 692 is configured to stop the handling station 102 at different forward positions. In some embodiments, the stopping positions is adjusted by the operator.
FIGS. 7A-7B illustrate flow diagrams of a method for measuring hardness of the component using the semi-automated handling system 100 of FIG. 1 according to some embodiments herein. At a step 702, the component is loaded by an operator to the gripper of the handling station 102 with a measuring surface that faces upward direction. The measuring surface includes at least one of a first measuring surface or a second measuring surface. The handling station 102 includes a least one gripper, a rotary actuator, and a track. The measuring surface of the component is indented before placing to the at least one gripper. The handling station 102 being moveable along the track between a starting position and a measuring station. At a step 704, the handling station 102 is enabled by a control unit 110 to move towards the measuring station 106 from the starting position in a forward direction along the track after receiving a cycle start signal which depicts that the component is loaded to the at least one gripper. At a step 706, the component is clamped, using a fixture 104, at a first side, while the gripper holding the component at a bore of the component which is located at the center. At a step 708, at least one indentation image of the first measuring surface of the component is acquired, using the one or more cameras 108A-N. The first measuring surface is parallel to the one or more cameras 108A-N. At a step 710, the handling station 102 is enabled by the control unit 110 to move from the measuring station 106 to the starting position in a backward direction after de-clamping the component at the first side, while the gripper holding the component at the bore. At a step 712, the component is rotated using the rotary actuator for a pre-determined angle of degrees after reaching the starting position. The second measuring surface of the component faces the upward direction after rotating the component to the predefined angle. At a step 714, the handling station 102 is enabled to move towards the measuring station 106 from the starting position along the track. At a step 716, at least one indentation image of the second measuring surface of the component is acquired using the one or more cameras 108A-N. The second measuring surface is parallel to the one or more cameras 108A-N. The fixture (104) clamps the component at a second side while the at least one gripper (676) holding the component at the bore of the component. The handling station 102 is retracted to the starting position when at least one indentation image of the second measuring surface is acquired. At a step 718, hardness of the first measuring surface and the second measuring surface measuring is determined by processing the at least one indentation image of the first measuring surface and the second measuring surface of the component using an image processing unit. The component is unloaded from the gripper of the handling station 102. In some embodiments, the steps 712 to 716 can be neglected and proceed with the step 718 if the operator requires only a single face measurement.
[0061] The semi-automated system 100 utilizes less man power and handles one or more hands of the component for the indentation measurement and the hardness value of the component. The semi-automated system 100 with the same handling station 102, the fixture 104 and the measuring station 106 can be utilized for handling different components with different sizes and shapes for measuring hardness of the different components. The semi-automated handling system 100 may be an add-on to the Brinell Hardness Testing Machine, that enables the operator to retro-fit for measuring the hardness of the component.
[0062] FIG. 8 is a schematic diagram of computer architecture of an image processing system with the control unit 110 or the one or more cameras 108A-N, in accordance with the embodiments herein. A representative hardware environment for practicing the embodiments herein is depicted in FIG. 8, with reference to FIGS. 1 through 7B. This schematic drawing illustrates a hardware configuration of the image processing system with the control unit 110 or the one or more cameras 108A-N in accordance with the embodiments herein. The image processing system includes at least one processing device CPU 10 that may be interconnected via system bus 14 to various devices such as a random-access memory (RAM) 12, read-only memory (ROM) 16, and an input/output (I/O) adapter 18. The I/O adapter 18 can connect to peripheral devices, such as disk units 38 and program storage devices 40 that are readable by the system. The system can read the inventive instructions on the program storage devices 40 and follow these instructions to execute the methodology of the embodiments herein. The system further includes a user interface adapter 22 that connects a keyboard 28, mouse 30, speaker 32, microphone 34, and/or other user interface devices such as a touch screen device (not shown) to the bus 14 to gather user input. Additionally, a communication adapter 20 connects the bus 14 to a data processing network 42, and a display adapter 24 connects the bus 14 to a display device 26, which provides a graphical user interface (GUI) 36 of the output data in accordance with the embodiments herein, or which may be embodied as an output device such as a monitor, printer, or transmitter, for example.
[0063] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the invention.
,CLAIMS:I/We claim:

1.A semi-automated system (100) for measuring hardness of a component, characterized in that the semi-automated system (100) comprising:
a handling station (102) that comprises a plurality of tools to handle the component, wherein the plurality of tools comprise,
(i) at least one gripper (676) for holding the component at a bore of the component after an operator loads the component to the at least one gripper (676) with a measuring surface that faces upward direction, wherein the measuring surface comprises at least one of a first measuring surface or a second measuring surface, wherein the measuring surface of the component is indented before loading to the at least one gripper (676);
(ii) a rotary actuator (684) for rotating the component to a predefined angle, and
(iii) a track (686) for guiding the handling station (102), between a starting position and a measuring position;
a fixture (104) that is configured to clamp the component; and
a measuring station (106) that comprises
one or more cameras (108A-N) that are configured to acquire at least one indentation image of the component; and
a control unit (110) that is configured to
enable the handling station (102) to move from the starting position to the measuring station (106) along the track (686) in a forward direction after receiving a cycle start signal which depicts that the component is loaded to the at least one gripper (676);
clamp, using the fixture (104), the component at a first side while the at least one gripper (676) holding the component;
acquire, using the one or more cameras (108A-N), at least one indentation image of the first measuring surface of the component, wherein the first measuring surface is parallel to the one or more cameras (108A-N);
enable the handling station (102) to move from the measuring station (106) to the starting position in a backward direction after de-clamping the component the first side while the at least one gripper (676) holding the component at the bore of the component;
rotate, using the rotary actuator, the component to the predefined angle after reaching the starting position, wherein the second measuring surface of the component faces the upward direction after rotating the component to the predefined angle;
enable the handling station (102) to move from the starting position to the measuring station (106) along the track (686);
acquire, using the one or more cameras (108A-N), at least one indentation image of the second measuring surface of the component, wherein the second measuring surface is parallel to the one or more cameras (108A-N), wherein the fixture (104) clamps the component at a second side while the at least one gripper (676) holding the component at the bore of the component; and
measure, using the image processing unit, hardness of the first measuring surface and the second measuring surface by processing the at least one indentation image of the first measuring surface and the second measuring surface of the component.

2. The semi-automated system (100) as claimed in claim 1, wherein the control unit (104) is configured to log and display one or more hardness values of the component in a user device.

3. The semi-automated system (100) as claimed in claim 1, wherein the plurality of tools comprises
one or more component stoppers (664A-N) that is configured to locate the component in a fixed position;
one or more preventers (666A-N) that is configured to prevent the component from being placed in a wrong position, that enables the component to be placed only in a desired position; and
a compensation unit (680) that is configured to adjust the measuring surface of the component parallel to the one or more cameras (108A-N).

4. The semi-automated system (100) as claimed in claim 1, wherein the track (686) comprises
a linear motion rail (688) that is configured to enable at least one of a linear forward motion or a linear backward motion of the handling station (102) in the track (686);
a handling station cylinder (690) that is configured to move the handling station (102) between the starting position and the measuring station (106); and
a handling station stopper (692) that is configured to stop the handling station (102) at different forward positions in the track (686).

5. The semi-automated system (100) as claimed in claim 1, wherein the measuring station (106) comprises
a lighting system (650) that is positioned below the one or more cameras (108A-N) for illuminating the measuring surface of the component while measuring the hardness of the component;
a lens (652) that is mounted on the one or more cameras (108A-N) to magnify the measuring surface of the component;
a mount (656) that is configured to couple with the one or more cameras (108A-N);
a camera holding arm (658) that is configured to hold the mount (656) along with the one or more cameras (108A-N);
a measuring camera stopper (660) that is configured to stop the mount (656) along with the one or more cameras (108A-N) at a top level; and
a measuring camera cylinder (662) that is configured to move the one or more cameras (108A-N) between a top position or a bottom position.

6. The semi-automated system (100) as claimed in claim 5, wherein the lighting system (650) comprises a height adjustment unit for adjusting the height of the lighting system (650) for illuminating the component.

7. The semi-automated system (100) as claimed in claim 5, wherein the mount (656) comprises
a height adjustment unit to adjust the height of the one or more cameras (108A-N) to acquire the at least one of indentation image of the component; and
a tilt adjust unit to tilt the one or more cameras (108A-N) to one or more positions to acquire the at least one of indentation image of the component to be measured.

8. The semi-automated system (100) as claimed in claim 1, wherein the fixture (106) comprises
an arm locating plate (632) that comprises an arm clamping cylinder (628), a clamp (630), and a V block (642) for arranging the measuring face of the component parallel to the one or more cameras (108A-N), wherein the arm clamping cylinder (628) is configured to clamp or de-clamp the component to a fixture surface using the clamp (630);
a top level fixture stopper (636) that is configured to stop the fixture (104) at a top level;
a plate locating cylinder (638) that is configured to position the arm locating plate (632) up before clamping the component and down after de-clamping the component; and
a bottom level fixture stopper (640) that is configured to stop the fixture (104) at a bottom level.

9. A semi-automated method for measuring hardness of a component comprising:
loading, by an operator, the component to at least one gripper (676) of a handling station (102) with a measuring surface that faces upward direction, wherein the measuring surface comprises at least one of a first measuring surface or a second measuring surface, wherein the handling station (102) comprises at least one gripper (676), a rotary actuator (684), and a track (686), wherein the measuring surface of the component is indented before placing to the at least one gripper (676), wherein the handling station (102) being moveable along the track (686) between a starting position and a measuring station (106),
characterized in that, the method comprises
enabling, by a control unit (110), the handling station (102) to move towards the measuring station (106) from the starting position in a forward direction along the track (686) after receiving a cycle start signal which depicts that the component is loaded to the at least one gripper (676), wherein the measuring station (106) comprises one or more cameras (108A-N) and the control unit (110);
clamping, using a fixture (104), the component at a first side while the at least one gripper (676) holding the component at a bore of the component;
acquiring, using the one or more cameras (108A-N), at least one indentation image of the first measuring surface of the component, wherein the first measuring surface is parallel to the one or more cameras (108A-N);
enabling the handling station (102) to move from the measuring station (106) to the starting position in a backward direction after de-clamping the component at the first side while the at least one gripper (676) holding the component at the bore;
rotating, using the rotary actuator, the component to the predefined angle after reaching the starting position, wherein the second measuring surface of the component faces the upward direction after rotating the component to the predefined angle;
enabling the handling station (102) to move from the starting position to the measuring station (106) along the track (686);
acquiring, using the one or more cameras (108A-N), at least one indentation image of the second measuring surface of the component, wherein the second measuring surface is parallel to the one or more cameras (108A-N), wherein the fixture (104) clamps the component at a second side while the at least one gripper (676) holding the component at the bore of the component; and
measuring, using an image processing unit, hardness of the first measuring surface and the second measuring surface by processing the at least one indentation image of the first measuring surface and the second measuring surface of the component.

10. The semi-automated method as claimed in claim 9, wherein the semi-automated method comprises,
logging and displaying one or more hardness values of the component in a user device.

Dated this, 15th March, 2022

Arjun Karthik Bala
(IN/PA 1021)
Agent for Applicant