Industrial manufacturing and nondestructive evaluation (NDE) are simultaneously undergoing their fourth revolutions, termed Industry 4.0 and NDE 4.0, respectively. Industry 4.0 requires NDE 4.0, which often requires the integration of artificial intelligence (AI) into the process of NDE data interpretation. The automotive manufacturing industry stands to greatly benefit from NDE 4.0, but its implementation presents many challenges that must be overcome. In this chapter, we discuss the benefits and challenges of Industry/NDE 4.0 in the context of automotive body manufacturing. We discuss signal/image processing and AI while elaborating on the roles of AI (particularly deep learning) in Industry/NDE 4.0. We then present an intriguing case study that highlights the considerations and challenges of transforming a preexisting NDE system for an automotive application—real-time integrated resistance spot weld analysis—for NDE 4.0, through the integration of AI. This case study involves discussion of the original automated NDE system, the development of a deep learning component for NDE data interpretation, and the considerations for the development of a feedback system including further development of an adaptive control algorithm for resistance spot welding. These elements (automated NDE data acquisition and big data storage, AI-based interpretation, feedback, and adaptive control) are essential to NDE 4.0, Industry 4.0, and the concept of zero-defect manufacturing in the automotive body industry. Finally, we discuss some other potential NDE 4.0 applications in automotive manufacturing—resistance spot welding (post-process inspection), resistance spot riveting, adhesive bonding, laser brazing, polymer joints, and projection welding—in which AI can be leveraged for automated NDE data interpretation.

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NDE in the Automotive Sector

  • Roman Gr. Maev,
  • A. Chertov,
  • Ryan Scott,
  • D. Stocco,
  • Andrew Ouellette,
  • A. Denisov,
  • Y. Oberdorfer

摘要

Industrial manufacturing and nondestructive evaluation (NDE) are simultaneously undergoing their fourth revolutions, termed Industry 4.0 and NDE 4.0, respectively. Industry 4.0 requires NDE 4.0, which often requires the integration of artificial intelligence (AI) into the process of NDE data interpretation. The automotive manufacturing industry stands to greatly benefit from NDE 4.0, but its implementation presents many challenges that must be overcome. In this chapter, we discuss the benefits and challenges of Industry/NDE 4.0 in the context of automotive body manufacturing. We discuss signal/image processing and AI while elaborating on the roles of AI (particularly deep learning) in Industry/NDE 4.0. We then present an intriguing case study that highlights the considerations and challenges of transforming a preexisting NDE system for an automotive application—real-time integrated resistance spot weld analysis—for NDE 4.0, through the integration of AI. This case study involves discussion of the original automated NDE system, the development of a deep learning component for NDE data interpretation, and the considerations for the development of a feedback system including further development of an adaptive control algorithm for resistance spot welding. These elements (automated NDE data acquisition and big data storage, AI-based interpretation, feedback, and adaptive control) are essential to NDE 4.0, Industry 4.0, and the concept of zero-defect manufacturing in the automotive body industry. Finally, we discuss some other potential NDE 4.0 applications in automotive manufacturing—resistance spot welding (post-process inspection), resistance spot riveting, adhesive bonding, laser brazing, polymer joints, and projection welding—in which AI can be leveraged for automated NDE data interpretation.