This workflow description explains how the Supervisor configures the Component Cleanliness Testing workflow for the Operator who acquires images and uses Intellesis object classification models for the particle type differentiation. Particle height measurement is performed.
Technical Cleanliness Standard Selection
Provides a list of the available standards for the TCA module to be used for the analysis with ML-based object classification. Preselected is: VDA 19.1 Extended Analysis - Free Analysis with ML Object Classification. Only standards with the addition "Component Cleanliness with Object Classification" may be used for object classification.
- Load the available standards to the job template.
- Select the standards that are relevant for the operator's analysis, see Technical Cleanliness Standard Selection Tool.
Group
Group for Input Form loop, Tiles Measurement Area and Split Image workbenches.
The Define Outputs tool does not display any entries. Therefore, editing is not possible.
Loop
Loop for Input Forms.
Iteration of all working steps within the loop definition.
- Configure the number of loops the tasks in the next loop will perform.
- Sets the working steps for the operator, see Loop Task.
Input Form
In the Form Selection tool, input forms are provided.
- In the Create Form Image tool, configure the size of the input form image in the report.
- Select from the set of pre-defined input form templates an appropriate input form. For component cleanliness one input form per extraction method is provided and furthermore one general form with minimum content.
- Add the customer data to the corresponding file. The Operator selects the customer data.
The customers are managed with an Excel file. This file is stored per default here: C\ProgramData\Carl Zeiss\ZENcore\Customer.Contacts.xlsx
The form is displayed in the report, see Form Selection Tool and Create Form Image Tool.
Tiles (measurement area)
Configures the settings of the specimen acquisition.
- Configure the image acquisition and save it as individual setting in the Camera tool.
- Perform a shading correction.
- Adjust tile regions to the specimen area to be analyzed, and save it as individual setting in the Camera tool.
- Verify the focus points
See
- Extended Camera Tool
- Light Path Editing Tool
- Tiles Setup (measurement area) Tool
- Focus Correction Tool
The operator uses this settings for the specimen acquisition.
Split Image
Splits n tile region images into n individual overview images.
Default: Run silent
We recommend not to change the default parameters.
See Split by Dimension Tool.
Loop
Iteration of all working steps within the loop definition.
- Select the number or range of loop iterations. The default value is Batch processing, i.e. the number of iterations is determined by the setting in the first loop.
We recommend not to change the default values.
The operator will not see these settings, see Loop Settings Tool.
Image Processing
Changes the image format to 8 bit.
Default: Run silent
We recommend not to change the default parameters.
See Convert Pixel Format Tool.
Image Channel Mapping
Determines the channel allocation for image analysis.
Default: Run silent
No parameters are accessible.
See Image Channel Mapping Tool.
TCA Analysis Task Group (Component)
Provides the image analysis setting for component cleanliness.
The Technical Cleanliness Analysis setting is applied by default to determine the particle types, i.e. metallic-shiny, non-shiny, and fiber.
We recommend not to change the default parameters.
The operator will not see these settings.
See Load Setting Tool
Frame Setup
Sets up and adds a measurement frame to the image. Only the area inside the frame is used for the analysis. The area of the measurement frame is retrieved from the Tiles (measurement area) tool.
Default: Run silent
Activated: Uses Tile Region Geometry, i.e. the measurement frame is retrieved automatically from the configured tiles regions, see
- Frame Setup Tool
- Tiles Setup (measurement area) Tool
Particle Segmentation (Components)
Extracts objects from the background by applying the pre-defined relative threshold range.
- Adjust the Relative Threshold if required. The Relative Threshold refers to the Relative Image Brightness (Luminosity).
Methods defined by the standards for component cleanliness:
- Standard Analysis
The threshold setting shall not be modified. - Extended Analysis - Free Analysis
The threshold setting can be adjusted if required.
See Concept of Relative Image Brightness and Relative Threshold.
The operator uses these values for the image segmentation, see Particle Segmentation Tool (Components).
Region Filter
Applies a filter to Image Analysis results.
Default: Run silent. Feret Maximum is activated and set to a minimum of 5 µm for component cleanliness and to 1 µm for oil cleanliness.
Note: Only relevant for oil job templates: the default region filter setting in all oil job templates is by default 1 µm for the minimum particle size and required for SAE AS 4059. This setting increases the analysis time. For oil standards with a size classification starting from 5 µm the region filter setting might be adapted accordingly.
In the Image Gallery, all particles are displayed from 5 µm length onwards for component cleanliness testing and 1 µm length onwards for oil cleanliness testing.
Measurement Data
Shows measurement results for the detected particles after segmentation and image analysis.
Default: Run silent
The Measurement Data tool displays the particle results. The calculation is performed with default values in the background, see Measurement Data Tool.
The operator will not see these settings.
Intellesis Object Classification
After the image has been analyzed, you use a trained model for ML-based object classification; here, you classify particles. The results of the Intellesis Object Classification are integrated into the standard calculation, such that there are no further adjustments needed.
Depending on your specimen, retraining of the object classification model might be necessary to adapt the particle type differentiation to your needs. The training of object classification models requires licensing of the AI Toolkit.
See:
Default: Run silent.
The object classification model for POL-135 POL-90 images is preselected. If you use different POL channel combinations, select the corresponding object classification model accordingly.
See
Standard Specific Settings
Configures specific parameter for the standard based calculation.
Default: Run silent
- Select the type of membrane filter in use.
- This determines the allowed range for the occupancy rate as defined by the standard.
- Adjust settings for the Normalization Parameter.
- Select whether the particle size class All shall display the results including fibers or not.
- Select how many of the largest particles per type you want to add to the report.
- The coordinates of all pre-selected particles will be added to the position list with EDF.
- Optionally, you can add the Equivalent Spherical Method (Components) tool to the workbench. The operator can adjust the Measurement Frame Area of the Frame Setup tool.
- These settings are conducted automatically in the operator workflow.
See
- Occupancy Rate (Components) Tool
- Normalization Parameter (Components) Tool
- Type Classification for Class "All" Tool
- Cleanliness Classification (Length) Tool
- Particle Gallery (Report) Tool
- Equivalent Particle Area (Components) Tool
Switch
Changes between the branches.
- Select the active branch according to the operator's needs, see Configuring the TCA Job Template by Switching the Active Branch.
You have the following options:
Size Distribution Live. See Size Distribution Live - Branch
Size Distribution Live & EDF/Position List. This is a prerequisite for the selection of the height measurement branch. See Size Distribution Live EDF/Position List - Branch
Size Distribution Live
Displays a group of tasks for workflow steps demanding hardware control. The corresponding task group is loaded.
No further action required.
See Configuring the TCA Job Template by Switching the Active Branch.
Size Distribution (Live)
These workflow steps are only visible for the active branch Size Distribution Live.
No further action required.
See:
- Size Distribution View
- Standard Result Selection Tool
- Displayed Normalization Tool
- Cleanliness Classification (Length) Tool
- Specimen Overview Tool
- Statistical Analysis Tool
- Result Approval Tool
- Occupancy Rate (Components) Tool or Occupancy Rate (Oil, Lubricants) Tool
Switch
Changes between the branches.
- Size Distribution Live & EDF/Position List branch is selected.
- Select the branch according to the operator's needs.
You have the following options:
With Height Measurement
Without Height Measurement
For information on the branch switches, see Configuring the TCA Job Template by Switching the Active Branch.
With Height Measurement
Displays a group of tasks for workflow steps demanding hardware control.
The corresponding task group is loaded.
No further action required.
See Configuring the TCA Job Template by Switching the Active Branch.
Interactive Height Measurement
Only visible with active branch With Height Measurement.
Enables to perform interactive height measurements.
To perform the interactive particle height measurement conduct manual focusing as described:
- Manually define the z-position at the membrane filter beside the selected particle as lowest position.
- Manually define the z-position at the top of the particle as highest position.
- The absolute difference between both z-values is the determined particle height.
See Interactive Particle Height Measurement Tool.
Position List with EDF
If zero particles are found, for example, in a blank test, this step is skipped.
An EDF image is created.
Acquires automatically an EDF image of the largest particle per type for the particle gallery in the report. The corresponding particle coordinates are saved by default in the Position List tool. The displayed number of particles per type cannot be modified in the EDF step. Note: The total number of particles per type is defined in the Standard Specific Settings workbench in the Particle Gallery (Report) (Components) tool.
Define the initial microscope and camera setting. Adjust the step size for the automated EDF acquisition.
See:
- Light Path Editing Tool
- EDF Setup (motorized focus) Tool
- Extended Camera Tool
- Position List Tool
- Select Active Camera
Reset Device Parameters
Changes the microscope hardware and camera settings. Restores the initial microscope and camera settings as defined in the Tiles (measurement area) workbench.
No further action required.
Split EDF Image
Splits the image scene into n images.
Default: Run silent
We recommend not to change the default parameters.
See Split by Dimension Tool.
Technical Cleanliness Results Output
Configures the layout of the gallery images in the report document and enables HYDAC Process Data Extraction.
With Shuttle & Find: enables the export of an EDS file with particle positions.
We recommend not to change the default parameter for the gallery image layout.
- Add the file path to where the HYDAC parameter XML file is stored.
See:
- HYDAC Data Extraction Tool
- With Shuttle & Find, see EDX File Export Tool
TCA Report
This component cleanliness specific workbench creates a TCA report for each specimen.
- In the Template Selection tool, the default report template is pre-selected.
- In the Display Settings tool, select a particle counting result, one or more chart types, and one or more particle types. Select System Properties to have the system properties displayed in the report.
- In the Gallery Setting tool, set the image count per row.
- The TCA report is configured for the operator. Note: The total number of particles per type is defined in the Standard Specific Settings workbench in the Particle Gallery (Report) (Components) tool.
See
- Template Selection Tool
- Chart Selection Tool
- Gallery Setting Tool