Static, dynamic thermal imagery systems for evaluating automotive painted structures

This work presents two implementation modes of thermal imagery systems, to evaluate automotive painted structures mainly car-shells and fuel containers. The non-intrusive evaluation is done through passive (static) and active (dynamic) thermography systems. Passive implementation employs built-in heat agitation sources in the process-chain, while the active system utilizes an external, controlled perturbation sources. The coated structures are evaluated from two perspectives; protective aspect, which include coat thickness, adhesion and pinholes. Aesthetics inspection focuses on contaminants detection and layer uniformity. The work discusses each case study through theoretical modeling and simulation to explain the detection theory, and further present laboratory testing results under controlled conditions. The actual system implementation is also discussed, with the challenges identified and the mitigation procedures shown. Further, novel image processing routines are introduced to explain the acquired scans processing, and problems with current commercially available routines. Finally, Results from actual pilot-runs are discussed and future improvements stated.