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Technical Cleanliness VDA 19 Analysis System for Auto Parts

Professional instruments, standardization

Analysis process based on ISO16232, VDA19 

High-performance particle size testing system

Test results traceable,generate results and reports

Simple operation, capture images fast and efficient

Automatic compensation ,each  image is clear, seamless browsing

Used in auto parts, aerospace, and hydraulic lubrication industries

Satisfy Volkswagen, BMW, GM, Ford and other major automakers

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DJ-CA100 Cleanliness Analysis System

High-performance Technical Cleanliness Inspection System

 

 

Applications

DJ-CA100 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.

 

Features

HD Optical Microscopic

Adopt HD Microscopic with a large zoom ratio, the zoom body is adjustable from 0.75-4.5X, and the total magnification is adjustable from 7.5-45X, suitable for Testing of impurities above 15 microns; 5MP color CMOS digital camera, pixel size 2.2× 2.2 μm, which meets the requirements of at least 10 pixels arranged on the maximum length of particles specified in the VDA19.1-2015 and ISO 16232-2007 standards;

 

High-precision scanning platform

 

Using high-precision two-axis electric scanning platform and high-precision auto-focusing system (optional), one-key auto-focusing of the filter membrane can be used to make the scanning accuracy more accurate, make the Testing uniform, and the intelligent cleanliness analysis software can automatically take pictures, Automatic focus, automatic control scanning, automatic identification and analysis to ensure that the particles are not missed or misjudged, and the Testing efficiency is high;

The automatic inspection and analysis process automatically scans the entire sample (usually filter paper), automatically takes pictures, automatically recognizes, counts, and analyzes particles, automatically checks cleanliness, and automatically generates professional analysis reports;

X\Y\Z three-axis mouse automatic control

Maximum range 70×70mm*50mm

Maximum speed 120 mm/s

 

Digital camera

HD true color, HD, high-resolution, high dynamic response, USB3.0 high-speed interface, real-time acquisition and simultaneous capture of images; support Chinese and English display and input operations; and include an interface with the microscope, effective physics 5MP.

 

Internal automatic polarized light source (optional)

With a dedicated digital light source controller, the software automatically controls normal light and polarized light, automatically sets the brightness of the light source, scans the filter once, and realizes the identification of metal and non-metal reflective particles. Low power consumption, high-brightness LED, lifespan of up to 20,000 hours, lifelong maintenance-free.

 

Simple and intelligent operation interface, the scanning range and automatic or manual polarization mode can be set in the software.

 

 

 

Multiple testing standards

Support multiple national and international standards: including ISO4406, ISO4407, ISO16232, NAS1638, VDA19, GB/T 20082, GB/T 14039, etc.;

standards can be entered for automatic Testing of cleanliness and particle size; fiber statistics can be performed; The system regularly updates the latest standards.

 

Scanning sample and settings diversified

Supports scanning areas of various shapes: rectangular area, circular area, etc., supports multiple scanning paths to meet the needs of various applications;

 

 

Auto-capture, positioning, and retrospective remake  

Auto-capture in the scanning process, auto-save, progress is visible in real time; photo information save to the database and simply to inquire;

And the information and pictures of the sample can be encrypted to prevent unauthorized viewing and modification. Provides the viewing and checking function of the field of view pictures, which can realize the functions of Positioning backtrack, fixed-point view or re-photograph of each field of view.

 

Innovative automatic polarized light technology, scanning the filter once, realize the identification of metallic and non-metallic reflective particles

The cleanliness testing system adopts innovative automatic polarized light technology. It only needs to scan the filter film once to appraisal the metallic and non-metallic reflections of the particles on the filter film. Compared with the traditional polarized light technology, the filter film needs to be scanned twice (1 time under orthogonal polarized light and 1 time under parallel polarized light), the scanning Testing time is doubled.

 

The system can auto-set the prescribed exposure time and threshold in compliance with VDA19.1-2015

It can auto-set the prescribed exposure time and threshold, perform sample testing to meet the requirements of the above-mentioned standards. At the same time, the functions of manual exposure and manual threshold are still retained, and users can freely choose according to their needs.

In order to make the analysis results comparable,VDA19.1-2015 has clearly stipulated the threshold parameter of the image gray scale of the optical microscope that uses the polarization to distinguish between particles and the background of the filter film.: the maximum gray value of the filter film background must be set At 55%±5% of the entire gray value (by adjusting the light source brightness and camera exposure time), the binary threshold is set at 70% of the maximum gray value, and the part on the left side of the gray threshold is recognized as particles.

 

Supports super-large particles across the field of view and auto-calibration the offset, so that pictures can be seamlessly stitched.

The system auto-recognizes particles, auto-analyzes particle types, auto-counts particle parameters, and supports modification of particles; provides multiple statistical analysis tools: particle list, statistical results, etc.;

 

 Measurement statistics and analysis

The system auto-recognizes particles, auto-analysis particle types, and auto-counts particle parameters. multiple statistical analysis tools can be provided: particle list, statistical results, etc.;

 

 

Cleanliness Testing Report (VDA19)

Support template report generation mode, including statistical data, rating, filter picture, maximum particle photo and other information; Multiple report modes are available.

Microscopic image analysis

Scale

4.3801 μm/Pixel

Analysis diameter[mm]

46.31

Particle count

26585

Filter membrane coverage

0.55%

Standard

VDA19

Class

X range μm

Total All (Except fiber)

Total Metal

Total Fiber

B

5<=X<15

11619

10

0

C

15<=X<25

6954

14

0

D

25<=X<50

5477

49

0

E

50<=X<100

1775

97

0

F

100<=X<150

406

134

0

G

150<=X<200

158

105

0

H

200<=X<400

139

118

19

I

400<=X<600

10

9

8

J

600<=X<1000

6

6

6

K

1000<=X<1500

2

2

5

L

1500<=X<2000

0

0

1

M

2000<=X<3000

0

0

0

N

X>=3000

0

0

0

Testing sample image

 

 

Regular image

 Polarization image

No. 1 non-metallic particles 572.25 X 171.33 μm

 

Area = 71282.89μm2

Long axis = 572.25μm

Short axis = 171.33μm

Circumference = 1568.47μm

Length-width ratio = 0.30μm

Shape ratio = 0.28μm

Center coordinates [7922.0,7763.9]

particles type = Non-Metal

No. 2 non-metallic particles 396.85 X 168.42 μm

 

Area = 19444.28μm2

Long axis = 396.85μm

Short axis = 168.42μm

Circumference = 1499.89μm

Length-width ratio = 0.42μm

Shape ratio = 0.16μm

Center coordinates [6654.9,4611.2]

particles type = Non-Metal

No. 1 metal particle 1436.59 X 434.10 μm

 

 

Area = 411476.21μm2

Long axis = 1436.59μm

Short axis = 434.10μm

circumference = 5221.75μm

Length-width ratio = 0.30μm

Shape ratio = 0.25μm

Center coordinates [6455.9,9917.5]

particles type = Metal

No. 2 metal particle 1171.79 X 230.73 μm

 

Area = 147045.55μm2

Long axis = 1171.79μm

Short axis = 230.73μm

Circumference = 3263.66μm

Length-width ratio = 0.20μm

Shape ratio = 0.14μm

Center coordinates [4678.7,7678.0]

particles type = Metal

No.1 largest fiber particle 1977.19 X 2648.01 μm

 

Area = 27003.28μm2

Long axis = 1977.19μm

Short axis = 2648.01μm

Circumference = 5363.93μm

Length-width ratio = 1.34μm

Shape ratio = 0.01μm

Center coordinates [3570.4,6157.0]

Particle type = Fiber

No.2 largest fiber particle 1311.49 X 1253.41 μm

 

Area = 15357.81μm2

Long axis = 1311.49μm

Short axis = 1253.41μm

Circumference = 3467.01μm

Length-width ratio = 0.96μm

Shape ratio = 0.01μm

Center coordinates [7672.8,4207.4]

Particle type =Fiber

Conclusion

Conformity

 

 

Supply List

No.

Item

Specifications

QTY

Unit

Remarks

1

HD optical microscope

Olympus, Nikon

1

Set

Include in quotation.

2

High precision electric scanning platform + holder

 

1

Set

3

High-precision autofocus system

 

1

Set

4

Cleanliness analysis software

V1.1

1

Set

5

Manual polarizing system

 

1

Set

6

Filter membrane positioning tooling

 

1

Set

7

Membrane clamp

 

1

Set

8

Scan platform control box

 

1

Set

9

CCD HD camera

 

1

Set

10

Computer

Lenovo

1

Set

11

Dongle serial number

 

1

Set

12

Documents (Manual, QC)

 

1

Set

Note:

The DJ-CA100 Cleanliness Analysis System can use wide range of optical microscope from China made to Olympus, Nikon, Leica.

The Manual polarizing system also can be Automatic polarizing system.

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