CA15A Technical Cleanliness Analysis System

Summary

This analysis system is used for cleanliness testing of automotive component samples. It can automatically count and analyze the type, size, and quantity of contaminant particles on the filter membrane, and classify them by size grade.

It meets the specification requirements for component cleanliness testing of powertrain plants such as VDA19, ISO16232, NAS1638, ISO4406, ISO4407, as well as those of Volkswagen, BMW, Ford, Mercedes-Benz, General Motors, etc. It can issue standard data reports compliant with the above specifications and has the capability to customize data reports.

Application

CA15A Technical Cleanliness Analysis System full compliance with the requirements of VDA 19.1-2015, ISO 16232, ISO4406 and ISO 4407, QV11111 and customer-defined standards. Adopted optical polarization technology, manually rotate the polarization device, the metallic luster reflection properties of all pollutants on the entire filter can be determined by two scans. At the same time, according to the morphological definition of fiber in VDA19.1 (stretch length/maximum inscribed circle diameter>20, maximum inscribed circle diameter≦50 microns), the classification and classification of the following four types of particles can be quickly and automatically completed within a few minutes. Size measurement: reflective particles, reflective fibers, non-reflective particles, non-reflective fibers.

Performance Features

1.The scanning and evaluation time for a single filter membrane should be controlled within 3 minutes (under the condition of a 3× objective lens, with a total magnification of no less than 250×).

2.The analysis can accurately distinguish metal particles, non-metal particles, and fibers, so as to have standard data basis for judgment.

3.The research-grade stereomicroscope with high depth of field, by virtue of its ultra-high depth of field and the new 4th-generation filter membrane clamping device, perfectly solves the problem of failure to capture all sharply focused images during scanning caused by the uneven surface of the filter membrane.

4.The software interface can be switched between Chinese and English.

5.The equipment automatically adjusts light intensity, performs multi-field automatic scanning, automatically collects images, and conducts automatic particle statistical analysis.

6.The equipment can accurately and automatically focus on and calculate the sizes of both large and small particles in the same scanning area.

7.It can classify and determine grades according to length grades based on ISO16232-2018, VDA19-2015, NAS1638, ISO4406, ISO4407 and enterprise-defined standards, and can calculate the total length of fibers on the filter membrane.

8.In accordance with the ISO16232/8 grade setting, when the same standard sample is tested repeatedly for 10 times, the deviation of the total number of particles is less than 10%.

9.According to customer requirements, particles of different sizes ranging from 5μm to 3000μm and above can be classified, counted and evaluated.

10.It can also accurately identify large particles with a diameter of more than 2mm. The system can automatically measure and calculate the size parameters of a single particle, such as area, width, and inscribed circle.

11.Operators can freely add the functional items that need to be reflected in the report in the software, and the software has an automatic memory function. It abandons the traditional way of selecting the corresponding template.

12.After scanning the filter membrane, it should have the capabilities of automatic particle statistics, automatic thresholding, and automatic particle identification without human intervention to reduce misoperations. However, it retains the functions of manually modifying the scanning results so as to splitting or associating particles of any shape.

13.Image acquisition device: a color high-definition camera, which can cooperate with an automatic microscope to perform automatic color balance, automatic scanning, and automatic image acquisition.

14.The system should have the ability to restore the color of particles to facilitate the naked eye to distinguish particles with different metal colors.

15.After a single scanning and evaluation, the software should be capable of reselecting the analysis area for re-analysis (this action should not require re-scanning the filter membrane), so as to extract particles that may be lost at the edge of the filter membrane.

16.Equipped with a high-precision automatic scanning stage with free travel, featuring both automatic and manual control modes. The overall accuracy of the scanning stage and equipment as well as the detection results are ultimately controlled by standard blocks.

17.The cleanliness analysis report shall include product model, customer name, inspection requirements, inspection date, inspection equipment model, inspector, inspection pictures, evaluation results, etc. The cleanliness analysis report can be saved and printed.

18.Evaluate the total number of contaminants per filter membrane, the total number of contaminants per part, and the total number of contaminants in the projected area of 1000cm² proposed in the evaluation results according to VDA19-2015, and present them in the form of a report.

19.The software can automatically stitch scanned images and store the scanned image of the entire filter membrane; the stored filter membrane images can be retrieved at any time for re-analysis, storage, and automatic export of office and word reports; the particle grades in the report template can be set according to user needs.

20.Equipped with a dedicated filter membrane holder. Once the filter membrane is placed, it can be directly scanned without repositioning, and it is compatible with filter paper specifications ranging from Ф47mm to Ф50mm.

21.The scanning data performance of nylon mesh woven membranes is the same as that of surface filter membranes, and the results are not affected by the mesh.

22.System calibration ruler, specification: 1/100μm

23.To ensure the reliability of equipment accuracy, standard slices (OPTO particle standard slices) used by benchmark host factories shall be provided for scanning and verifying the equipment, which are used for calibrating the equipment accuracy.

Technical Parameter