Faris

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Visual Faris
USER MANUAL
Visual Faris Edition : February 2012 User Manual
Title : VISUAL FARIS User Manual
Author : Moreno Savio
Rights : reserved to Bosello High Technology srl
All rights reserved. No part of the contents of this document may be reproduced or transmitted in
any form or by any means without the express written permission of Bosello High Technology.
All trademarks, brands, logos and names are the property of their respective owners.
The author and publisher have made every effort in the preparation of this book to ensure the
accuracy of the information. However, the information contained in this book is sold without
warranty, either expressed or implied. Neither the author, Bosello High Technology nor its dealers
or distributors will be held liable for any damages caused or alleged to be caused either directly or
indirectly by the information contained in this book.
Information in this book is subject to change without notice and does not represent a commitment
on the part of Bosello High Technology.
© 2012 Bosello High Technology
Edition : February 2012
This edition do apply only to Visual Faris releases from February 2012 on.
Printed in Italy
Bosello High Technology All rights reserved 2

Contents
CONTENTS ...................................................................................................................................................................... 3
INTRODUCTION ............................................................................................................................................................ 6
EQUIPMENT ................................................................................................................................................................... 7
INTERFACE WITH X-RAY UNIT................................................................................................................................ 8
SAMPLE CONCEPT ....................................................................................................................................................... 9
SAMPLE MANAGEMENT .......................................................................................................................................... 12
PROGRAMMING AREA .................................................................................................................................................... 13
New Sample .............................................................................................................................................................. 14
STORAGE AREA ............................................................................................................................................................. 15
BACKUP AREA ............................................................................................................................................................... 17
FOLDERS SETTINGS ........................................................................................................................................................ 18
SAMPLES DISPLAY..................................................................................................................................................... 18
SAMPLES DISPLAY..................................................................................................................................................... 19
IMAGE MANAGEMENT ............................................................................................................................................. 20
RESTORE THE SAMPLE IMAGE ....................................................................................................................................... 20
COPY THE ACQUIRED IMAGE TO THE SAMPLE BUFFER ................................................................................................... 20
LOADING AN IMAGE TO THE ACQUISITION BUFFER ........................................................................................................ 21
SAVE DISPLAYED IMAGE ................................................................................................................................................ 21
SAVE USER DEFINED IMAGE AREA ................................................................................................................................. 22
SELECT DISPLAYED IMAGE ............................................................................................................................................ 23
IMAGE ACQUISITION ................................................................................................................................................ 24
ACQUISITION OF A SINGLE IMAGE .................................................................................................................................. 24
CONTINUOUS ACQUISITION............................................................................................................................................ 24
IMAGE PROCESSING ................................................................................................................................................. 26
ENHANCED IMAGE ZOOM ............................................................................................................................................... 26
LOOK UP TABLE ............................................................................................................................................................. 26
PROFILE ......................................................................................................................................................................... 27
VIRTUAL DEFECTS GENERATOR ..................................................................................................................................... 28
SHOW DEFECTS FEATURES ............................................................................................................................................. 29
SAMPLE PROGRAMMING ........................................................................................................................................ 30
ACQUISITION CONTROLS ............................................................................................................................................... 31
ACQUISITION REPORT .................................................................................................................................................... 33
PRE-PROCESSING ........................................................................................................................................................... 34
Definition of the Regions Of Interest ........................................................................................................................ 35
The Line .................................................................................................................................................................................. 37
The curve................................................................................................................................................................................. 37
The region ............................................................................................................................................................................... 38
Colouring ................................................................................................................................................................................ 39
ROI.......................................................................................................................................................................................... 40
Modifications .......................................................................................................................................................................... 41
ROI selection........................................................................................................................................................................... 41
Image alignment ....................................................................................................................................................... 42
Roto-translational matching .................................................................................................................................................... 43
Horizontal and vertical matching ............................................................................................................................................ 45
Rotational matching for wheels............................................................................................................................................... 46
Remove details.......................................................................................................................................................... 47
Raised metal............................................................................................................................................................................ 48

Wheel rim : equalize ............................................................................................................................................................... 48

ID box ..................................................................................................................................................................................... 49
Mould Junctions ...................................................................................................................................................................... 49
Gray Scale Extension................................................................................................................................................ 50
Enhance Details........................................................................................................................................................ 51
PROCESSING .................................................................................................................................................................. 52
Morphological processing ........................................................................................................................................ 53
Drawing the ROP .................................................................................................................................................................... 55
General parameters.................................................................................................................................................................. 57
Foreign material processing..................................................................................................................................... 58
High density inclusion............................................................................................................................................................. 59
Medium-high density inclusions ............................................................................................................................................. 61
POST-PROCESSING .................................................................................................................................................... 63
RESULTS INTERPRETATION................................................................................................................................... 64
REGIONS OF MAGNIFICATION DEFINITION ...................................................................................................................... 65
STANDARDS DEFINITION ................................................................................................................................................ 70
REJECTION STATISTICS .................................................................................................................................................. 71
RESET INSPECTION RESULTS .......................................................................................................................................... 71
REGIONS OF BELONGING .............................................................................................................................................. 72
Programming........................................................................................................................................................................... 72
Processing ............................................................................................................................................................................... 72
Execution ................................................................................................................................................................................ 73
REGIONS OF REJECTION CODING (REJECTIONCODINGAREAS)...................................................................................... 74
DEFECT STATISTICS ....................................................................................................................................................... 75
PROGRAMMING FUNCTIONS TOOLBAR............................................................................................................. 76
PROGRAMMING FLOW CHART ............................................................................................................................. 77
ON-LINE INSPECTION ............................................................................................................................................... 79
PRODUCTION COUNTERS................................................................................................................................................ 80
PRODUCTION IMAGES VIEWER ....................................................................................................................................... 81
PRODUCTION STATISTICS ...................................................................................................................................... 82
SETTINGS....................................................................................................................................................................... 85
Production statistics options..................................................................................................................................... 85
Save bad images options........................................................................................................................................... 86
Inspection result with prefix A coding ................................................................................................................................... 87
Save inspection images options. ............................................................................................................................... 88
RESET PRODUCTIONREPORT ......................................................................................................................................... 89
PRODUCTION VIEWER .................................................................................................................................................... 89
PRODUCTION EXPLORER ................................................................................................................................................ 89
COMPACT DATABASE .................................................................................................................................................... 89
DIAGNOSTICS .............................................................................................................................................................. 90
IMAGE QUALITY ............................................................................................................................................................ 90
CAMERA ALIGNMENT .................................................................................................................................................... 91
OPTICAL CHAIN SENSITIVITY ......................................................................................................................................... 91
COMPARE SAMPLE AND ACTUAL IMAGE ........................................................................................................................ 91
MONITOR ...................................................................................................................................................................... 92
CONTRAST SENSITIVITY ................................................................................................................................................ 93
VIEW............................................................................................................................................................................... 94
DISPLAY CLASSIFICATION PALETTE FOR REFERENCE DEFECTS ...................................................................................... 94
ABOUT BOXES ............................................................................................................................................................. 95
VISUAL FARIS................................................................................................................................................................ 95
SYSTEM ......................................................................................................................................................................... 95

ACTUAL SAMPLE ........................................................................................................................................................... 95

WORKING PROGRAM ..................................................................................................................................................... 96
RESOURCES ................................................................................................................................................................... 96
SYSTEM UTILITIES .................................................................................................................................................... 97
LANGUAGES .................................................................................................................................................................. 97
VIRTUAL KEYBOARD ..................................................................................................................................................... 97
USER MANUAL .............................................................................................................................................................. 98
USER POLICY ................................................................................................................................................................. 99
User Registration.................................................................................................................................................... 100
Logon...................................................................................................................................................................... 101
Logoff...................................................................................................................................................................... 101
Show users list ........................................................................................................................................................ 101
Show connected user data ...................................................................................................................................... 102
Users actions traceability ....................................................................................................................................... 102
Show actions. .......................................................................................................................................................... 103
Enable easy logon................................................................................................................................................... 103
Levels accessibility table ........................................................................................................................................ 104
INSPECTION TIMINGS ................................................................................................................................................... 105
TROUBLESHOOTING............................................................................................................................................... 106
X-RAY INSPECTION IMAGES COLLECTION .................................................................................................................... 106
ONLINE PROCEDURES FOR IMAGES COLLECTION AND WORKING PROGRAMS BACKUP/RESTORE................................... 107
OPTIONS ...................................................................................................................................................................... 108
OFFLINE STATION ........................................................................................................................................................ 108
MULTI ENERGY............................................................................................................................................................ 108
REGIONS OF REJECTION CODING (REJECTIONCODINGAREAS).................................................................................... 108
GLOSSARY .................................................................................................................................................................. 109

Introduction
Visual Faris features state of the art of imaging technology for automatic defect recognition for
industrial X-ray applications.
This innovative, artificial vision system is totally designed and developed by Bosello High
Technology imaging research laboratories and provides reliable and effective diagnostic tools for
all applications that require quality control on X-ray images.
Visual Faris X-ray inspection consists of the processing of a series of images taken from a casting
in positions that have been programmed for inspection. A sample image is acquired for every area
of the part that requires inspection for internal discontinuities.
These images are then used and enriched with data during the programming process, which consists
of the settings of all the parameters and the necessary information for processing, analysis and
interpretation of the detected defects.
Visual Faris system consists of an image processing unit (PC) and proprietary image processing
software developed by Bosello H.T.
X-ray Inspection
Parts transportation
and manipulation Communication of
inspection results to
parts unloading
system
X-ray exposure of Analysis of

inspection views X-ray images on
ADR computer
Digitization of
X-ray images into
ADR computer

Equipment
The processing system is a PC based platform.
Further minimum characteristics of the PC are:
• 2048 MB RAM
• Hard Disk with a minimum capacity of 80 GB
• CD/DVD-ROM drive rewritable
• SVGA video card with 32 MB RAM bus AGP
• Frame grabber
• Ethernet card
• Keyboard and mouse
• SVGA monitor 19"
We reserve the rights to change or improve without prior notice.

Interface with X-ray unit
Visual Faris station.

Visual Faris interacts with the X-ray unit.
Visual Faris is responsible for :
• capturing triggered images
• x-ray images analysis and interpretation
• forwarding information regarding acceptability.
X-ray unit.
X-ray unit is responsible for:
• Part transportation in and out the X-ray cabinet

• Manipulation of parts inside the X-ray cabinet
• X-ray energy settings for each inspection view
• Triggering image acquisition to Visual Faris
• Handshake inspections results with Visual Faris

Sample concept
Visual Faris X-ray inspection consists of the analysis of a series of images taken from a casting in
different perspectives that have been programmed for the inspection. As soon as the part of the
casting to be inspected has been defined, a sample image is acquired for every position (view).
These images are then used and enriched with data during the programming process, which consists
of the setting of all parameters and information for processing, analysis and interpretation of the
detected defects.
From now on we will refer to the sample image and all relative programming data as the
“Sample”.
The collection of Samples related to a specific casting will make up the parts of a Working
program.
VIEW 1
+ processing data
SAMPLE 1
VIEW 2
+ processing data
SAMPLE 2
VIEW 3
+ processing data
SAMPLE 3

Each inspection view is linked to a Sample. A connecting rod for example may have three
"views"; one for the small eye, one for the shaft and one for the big eye. There will be a Sample
for every view composed of the sample image and its programming data.
If there is similarity in the views of the parts of the same casting, these views can be linked to a
single Sample – in this case there are several images for the same view coupled as one
representative Sample. Example: The inspection of a wheel rim provides a sequence of images
each of which shows a part of the rim. These images are almost similar and can be grouped together
to a single Sample that suffices for the whole series of rim images.
The programming of a certain number of Samples that equals the number of specified views
defines the inspection of a casting. The number of views (= the number of Samples) depends on
the number of parts that are to be inspected as well as their possible similarities.
Connecting View 2 In this example there are three parts of the piece to
rod inspect: the two eyes and the central shaft.
inspection Every single view is different and therefore
Samples for every single view must be created. At
the end of the programming the following situation
should conceptually be met:
View 1 Sample
1
View 2 Sample
2
View 3 Sample
View 1 View 3 3

This example shows a wheel with three areas to be

Wheel View 2 inspected: Rim, spokes and hub.
inspection 8 images are necessary to cover the whole
circumference of the rim; only 4 images for the
spokes, as they are alike; another 4 images to cover
the whole circumference of the hub. At the end of
the programming the following situation should
conceptually be found:
View Sample Valid for 8

1 1 images
View 3
View 1 2 2 images

3 3 images
A close link connects the geometrical and morphological characteristics of a casting with its
Samples. This close connection is essential for a correct analysis and interpretation of the results.
If a casting is modified (e.g. by a through hole) the existing Samples of this part of the casting
have to be updated. A new image has to be acquired and programmed for the relevant area.
The two main operations to create a Sample are: Acquisition of the sample image and the
programming of this image.
Image acquisition has to be made on site during the programming of the inspection by the CNC
that controls the system. In this phase the operator will be asked to provide data concerning the
number of images that belong to a view and refer to a single Sample.
Image programming can be performed on-line, or, by a stand-alone Visual Faris system, as
mentioned previously.

Sample Management
The menu entry “Samples manager” provides a set of functions with which to
operate the Sample data and images.
A Sample can be transferred from one memory device to another. It can also be deleted, saved,
restored, duplicated, etc….
This chapter will explore in detail all of these functionalities.
Each Sample can be imagined as a block of data. Although this block of data is composed of a set
of files, folders, images, etc… from a programming stand point, it doesn’t really matter what’s
behind the name Sample, nor the architecture that holds it.
Visual Faris allows the programmer to manage these Samples as a single and individual block of
data.
There are three main memory locations for sample management :
• $("( (. This is the area where Samples can be programmed.

• *,"((. This is the area where samples are stored.
Samples can be stored on any non-volatile memory device
available on the computer.
• .$(. This is the area where samples can be stored for backup
purposes. Samples can be stored on any non-volatile memory
device available on the computer.

Programming area
Sample programming takes place in this area.

All programming operations, such as data
entry, regions drawings, standards selection,
etc… are operated in the $("(
(.
The upper section of this window shows a list
box of all samples actually present in the
$("( (E
The lower section of this window shows the
image of the selected Sample.
Right click on one of the Samples name on
the left and a context menu shows up as
follows:
This
This button allows you to generate a new and empty Sample. See next
page.
This button allows you to save only selected Sample into the *,"(
(.
This button allows you to save all Sample into the *,"((.
This button allows you to close the Sample and remove it from the
$("( (. If a Sample is closed before the changes have
been saved, these modifications will be lost.

New Sample
This function creates a new and empty Sample . This dialog box shows up.
Use this button to

confirm the entered
data, create a new Sample
and close the dialog box.
Use this button to

close the dialog
box without
creating any new Sample.
Virtual keyboard
allows to type
characters and numbers into
edit boxes.
Sample identification data:
Name This field represents the Sample name.

Must be common to all samples that make part of a working program.
Max 100 chars. Not allowed chars are: . , : ; ” / = ? + * | \ < > ‘ ( )
View This field represents the index of the Sample within the working program
sequence.
Numeric values from 1 to 48
Working program This field represent the ID number for the inspection of the part.
Numeric values from 1 to 1024
There are two options:
1. Create a fully empty Sample; that is a sample image black and all data blank. Just enter the
identification data and press the confirmation button. A new sample is generated in the
$("( (.
2. Create a new Sample using an image taken from a file, leaving all data blank. Enter the
identification data, then the Create from file button will turn un-greyed. Click this button to
open the standard File Open Windows dialog box. Choose the file that contains the image
You want to use as a sample image. Once the file has been selected the New Sample dialog
box closes automatically. A new Sample is generated in the $("( (.

Storage Area
This is the area where sample are stored

*,"((E
Right click on one of the Samples name on

the left and a context menu shows up as
follows:

This function transfers one or more Samples from *,"(( into

$("( (. Samples which are already present in the
programming area will not be transferred twice.
This function transfers all Samples which have a code equal to the code
of the selected sample, from *,"( ( into $("(
(. Samples which are already present in the $("(
( will not be transferred twice. This function is not active in case of multiple selections. Only
one Sample has to be selected in order to activate this function.
This function has been designed in order to automatically open all Samples of a specific working
program.
This function deletes the selected Sample(s). This will permanently

delete the Sample(s) from the *,"(( without any possibility
or recovery.
This function transfers one or more Samples from *,"(( to

.$(.
This function generates a zip file of the selected Samples.

Zip file name will be formatted as follows:
“sample name.sampleindex.sample code date time.zip”

Backup area
This is the area where samples can be stored

for backup purposes.

.$(E
Right click on one of the Samples name on the

left and a context menu shows up as follows:
This functions transfers one or more Samples from .$( to

*,"((
This function deletes the selected Sample(s). This will permanently delete
the Sample(s) from the .$ ( without any possibility or
recovery.

Folders settings
This function allows setting up the default system folders. The following
dialog box will appear:
),"((
.$ (
Default folder for generic images

Default folder for zip files

Samples display
Sample images and data are displayed into a dedicated window.
Sample name is displayed into window title.

There are two rows of tool buttons to operate the sample images and data.

Image management
As mentioned above, there is a reference image for every Sample. This image can be captured at
Sample creation and can be eventually changed, but, in any case has to be a good representative of
the actual x-ray view of inspected part.
This image is used for programming and for possible further modification of the Sample data and
will be indicated from now on as sample-image.
Sample has another image buffer that can be loaded with images from cameras or from files. This
image buffer is used to test and debug the actual programming, and will be indicated from now on
as acquisition-image. When a Sample is just opened, acquisition-image and sample-image are
identical.
These two command buttons allows to show sample-image (SMP) or acquisition-
image (ACQ). There are more command buttons close to these two; they display
successive phases of the image processing and will be illustrated later. The writing on the button
that refers to the current image on the screen will be red.
Restore the Sample image

Choose this button to copy the sample-image (SMP buffer) into the acquisition-image
(ACQ buffer).
Copy the acquired image to the Sample buffer

Choose this item to replace sample-image with acquisition-image.
This is a very critical operation and should be operated only in case the actual sample-image no
longer serves as a functional representative of the actual x-ray view of inspected part.
This operation requires supervisor access.

Loading an image to the acquisition buffer

This function loads a filed image in the acquisition-image (ACQ). Select this function from the
sample toolbar or from the “Samples Manager” sub-menu. Image files shall be selected with the
Windows® Open File dialog box.
The image of this file will be loaded
into the buffer if its format is
compatible with the sample-image
format, otherwise, a dialog box will
explain that the two images have
different formats.
Open File dialog box has been
expanded with extra features such
as:
• Selected image preview.
• Grabber-specific image
formats.
• Image gallery.
Save displayed image

This function saves the displayed image into a file. Select this function from the Sample toolbar or
from the “Samples Manager” sub-menu. Image file destination and name shall be selected with the
Windows® Save File dialog
box. The displayed image will
be saved into the selected
directory with the typed name.
File format can be selected
within the available grabber
formats list box.

Save user defined image area

This function allows saving user defined portions of the displayed image into a file.
Press this button from the Sample

toolbar and then use left mouse button to
define a rectangle inside the image field
of view. Press left mouse button to fix
rectangle top-right corner, keep left
mouse button pressed and move mouse
to the bottom-right corner, then release
left mouse button.
At this point, the Save File dialog box
will appear automatically.
Select destination directory, type file
name, chose file format and press the
Save button.

Select displayed image

The following buttons comprise a portion of the Sample toolbar and allows access to some of the
most important Sample image buffers.
Sample-image
Acquisition-image
Acquisition image after pre-processing operations
Acquisition image after pre-processing and processing

operations
Acquisition image after pre-processing, processing, and threshold operations
Acquisition image after pre-processing, processing, threshold, and defect

features operations

Image acquisition
Acquisition of a single image

Choose this button to take a single frame of the camera and to insert it in the acquisition-image
(ACQ) buffer.
Continuous acquisition
Choose this item to start continuous acquisition into the
ACQ buffer. This button appears disabled in case actual
Sample is not compatible with actual imaging chain.
The following window will open:
Histogram.
Gary levels histogram is continuously updated at any
image frame coming from the imaging chain.
The image histogram represents the distribution of grey
levels; the horizontal axis represents all the grey levels,
the vertical axis the number of pixels with the same grey
level.
Integration.
Integration is a powerful noise reduction technique based
on the principle of summing a user defined number of
input frames together, and dividing the result by the same
number.
Noise is a random addition to the input. Consequently, the
mean value of the noise will rapidly fall towards zero as
more frames are summed together. The reduction math
law is proportional to the square root of the number of
frames summed. The number of frame added may be 1, 2,
4, 8, 16, 32, 64, 128, or 256. Integration performances
increases with a higher frames number, but, the integration time increases also; integration works
on the live input signal, this means that the frame rate is fixed by the video signal coming from the
imaging chain, a compromise must be taken between noise reduction level and integration time.

PerkinElmer panel functions.
These parameters are applied to images taken from all Perkin

Elmer panels type. This group of functions shows up if Visual
Faris is connected and configured to capture images from a
Perkin Elmer panel.
These parameters make part of the Sample data , and will be
applied to all images taken for the Sample.
Detector settings.
Camera gain : This parameter sets the gain factor of the detector. Values from 1 to 5
Camera rate : This parameter sets the over exposure factor of the detector. Values from 0 to 8
Look up table settings.

Oset : This parameter is the offset of the LUT. Values from 1 to 255
Sset : This parameter is the slope of the LUT. Values from 45 to 90
Activate frames cumulation.

If this check box is turned on, the integrated frames will not be normalized to the number of
collected frames. For example, if integration level is set to 4, at every acquisition the system grabs 4
frames , adds them together and then divides the results by 4. If this Activate frame cumulation is
turned on, the results will not be divided by 4. Which means , the resulted image will be 4 times
brighter than each single frame. This function is usefull when the cross section of the inspected part
is at the limit of the penetration power of the X-ray system.
High Dynamic Filters.

Images captured can be processed with a set of 5 filters, in order to provide the operator with
sharper images.
There filters do not make part of Sample data.
Show saturations.
Check this box to display saturated areas with colors. White saturations are red colored, while,
black saturations are blue colored. An optimal acquisition takes place when no black or white
saturations appear within the Regions of Interest of the image, this means that some saturated areas
might be left, but only if located outside the ROI of the X-ray view.

Image processing
Enhanced image zoom

Choose this command button from Sample toolbar to magnify and process the actual image. Once
selected a virtual lens will appear as shown in the picture:
The enhanced image zoom

is a virtual lens with a
magnification factor of 2. In
addition to that, a left mouse
click will apply a filter (0 ÷ 3) to
this part of the image; whereas a
right mouse click will apply
contrast sensitivity (1 ÷ 31).
Filter and gamma actual values
are displayed in the Sample
status bar.
Look up table
Choose this command button from Sample toolbar to apply a look up table.
This utility allows a grey level dynamic range

compression-expansion for better visibility on all
image areas.
Move mouse on this picture and press mouse left
button , keep left mouse button pressed and move
mouse around the picture to get the desired image
effect. Release mouse button to terminate the LUT
function. Press right mouse button on this picture
to return to linear grey level function.

Profile
The profile window reads out and graphically displays the grey-level counts from a single pixel
line. The line length, position and tilt can be changed with the mouse; press the left mouse button to
change the initial position of the line and move it to set direction and length.
To the right of the profile window a properties box gives some details regarding the measurements
of the grey level readout.
Use scroll bars to change the displayed grey levels dynamic range.
This allows expansion of fine profile details.
The edit box on top of scroll bars shows the actual maximum grey
level displayed on the picture.
The edit box on the bottom of scroll bars shows the actual
minimum grey level displayed on the picture.
Use this slider control and side edit boxes to display subsections
of the profile line.
Use this button re-expand line profile in case any subsection have
been applied.
Distance measurements can be executed between two line profile

points. Use left mouse button to fix start and end point, the
distance will be displayed in these edit boxes both in pixels unit
and in mm unit using the sample magnification factor.

Virtual defects generator
The sample toolbar provides four buttons that allow you to apply virtual defects on the
acquisition-image (ACQ) in order to verify the efficiency of the search engines set up for the active
Sample.
Available virtual reference defects are :
1. Gas porosity round ¼” .

2. Gas holes ¼” e ¾”.
3. Shrinkage cavity ¼” .
4. Foreign material denser ¼” e ¾”.
Press the selected defect type from Sample toolbar and apply it on the image by moving mouse on
the desired area and left-click. Right mouse button can be used to change defect levels.
Defect types and levels are displayed on Sample status bar.
The picture on the side shows an example; shrinkage

cavity has been selected; on the acquisition-image a
dotted, rectangular box will appear with dimensions
equal to the unit area (2” x 2”) containing a simulation
of reference defect. The rectangle and defect dimensions
are automatically adapted to the magnification factor of
actual mouse location (ROM, see relative chapter).
The system automatically
takes into account thickness
¼” and ¾” .
If the selected defect does not have any built in reference, the system
will notify the operator with a “not found” result. If the actual image
resolution is less than the defect diameter, the system will notify the
operator with a “not visible” result.

Sample program execution

Click on this command button to
execute the Sample program.
Possible defects will be identified and
coloured according to their levels.
Show defects features

Click on
this button
to execute Sample
program and
display defect
features. For every
identified defect,
the system gathers a
set of information.
These details are
grouped in the
properties box to
the right of the
image.

Sample programming
This chapter explains the operations required to set up the Sample program for detecting and
properly categorizing the discontinuities that may appear in the X-ray image.
Firstly, the Sample has to be loaded into the $("( ( either by creating a new Sample
or opening an existing one. Every addition or modification made during the programming will be
stored in the $("( ( .
Sample programming is divided into four fundamental steps that represent the first four items of
the “Programming” menu. They may contain cascading menus themselves.
Generally, the programming follows the same order as traced in the menu; alterations in this order
are admitted, especially in the case of modifying or adding data.
All the programming operations are directed to one Sample, in particular to the Sample that is
active at the moment of the selection of an item from the menu. If several Samples are open at the
same time, each of them may be in a particular phase of its programming but they are not
necessarily all at the same programming phase.
To avoid confusion and to keep ones attention on a single image we highly recommend
programming only one Sample at the same time, especially when starting from scratch. On the
other hand it can be useful to program two or more Samples at a time when specific data is to be
compared or when programming Samples of the same Working Program.

Acquisition controls
Choose this item from top menu or from program bar icon to configure the image acquisition
controls:
Copy actual settings to all samples of

actual working program
Exit without saving
Save and exit
Select “no-control” in any column to disable the corresponding control parameter.

• Integration: outlines the number of frames collected to grab the acquisition-image of the
actual Sample. Integration is a powerful noise reduction technique based on the principle of
summing a user defined number of input frames together and dividing the result by the same
number.
Integration performances increases with higher a frames number, but, the integration time
increases also. Integration works on the live input signal. This means that the frame rate is fixed
by the video signal coming from the imaging chain, in which case, a compromise must be taken
between noise reduction level and integration time.
• Smoothing (Low-pass filter): outlines the level of noise reduction. This function is faster than
Integration but generates a loss of image information proportional to the selected level.
• Maximum brightness variation allowed: outlines the tolerated percentage variance between
the average grey levels of the sample-image and the average grey levels of the acquisition-
image. The acquisition-image will not be accepted at the end of the processing if this value
is exceeded.
• Maximum misalignment allowed: This is a measurement in pixels. It determines how much

misalignment between the acquisition-image and the sample-image is acceptable at the end
of the processing.
• White saturation checking: indicates to the system that every area with a grey level higher
than the outlined maximum grey level percentage for the image is a defect area. Values are
indicated in percentage of the maximum grey level.
• Black saturation checking: indicates to the system that every area with a grey level lower
than the outlined maximum grey level percentage for the image is a defect area. Values are
indicated in percentage of the maximum grey level.
• Part integrity
This function has been designed to check part integrity within the ROI.
White saturate areas are being searched within the ROI and are classified as defects.
This control has been introduced to identify gross variations in the part , such as, missing areas ,
large cavities, etc….
This control operates within the ROI , with the following limitations :
1. First 5 pixels from the ROI borders are excluded from the analysis. This to avoid problems
in case image misalignment could not be completed compensated by matching functions.
2. White saturated areas left in the ROI will not be taken into account.

Acquisition report
Information and data about comparison between

acquisition-image (ACQ) and sample-image (SMP)
are available from the Acquisition report window.
This window can be activated from the main menu.
Results of acquisition controls are displayed for any

type of control enabled, such as brightness,
flickering or misalignment. For each type of control,
this window provides numerical data of measures
executed as well as results of comparison with
thresholds set in the acquisition controls.
ROI borders checks if any of the ROIs goes outside
the image area after realignment.
This means that actual value does exceed

threshold.
This means that actual value complies with
threshold.
This means that this control is not activated.
The “ROI borders” field provides information about the position of the ROIs after matching
alignment has been applied to the acquired image. If parts of the ROIs exceed the image borders,
the acquisition fails.
This happens when the image misalignment is significant or when the ROIs have been designed too
close to the image borders.
Press this button to re-execute all acquisition control measures. Any time this controls are
executed, the acquisition-image is corrected in terms of position within its buffer to
compensate for eventual misalignments that show up from the calculations. This means
that results may have small variations at any recalculation.
Press this button to exit .

Pre-processing
Pre-processing includes three operations.

Henceforth, we will call the areas of real interest for the image analysis R.O.I. (Regions Of
Interest). Image analysis will be limited inside the ROI.
To determine these areas it is necessary to keep the following factors in mind:
• ROI should contain casting areas that will not be eliminated after x-ray inspection, to avoid
useless analysis.
• ROI has to be shot in best X-ray conditions, with no saturations; white nor black.
• ROI surface has to be as perpendicular in relation to the X-ray beam as possible
Image
intensifier X-ray source
The picture above shows that the central part of the casting (coloured) satisfies all alignment
requirements, whereas the two side parts do not.
Even though parts of the casting do not comply with the requirements they can still be analysed
with Visual Faris. However, since the information from the images is limited, it will be difficult to
find the defects and to assess their real extent.
Taking this into consideration it is essential that the inspection positions are calculated to the best
operating conditions.
Determining the ROI aims at a fundamental purpose: to concentrate the system’s attention on the
Regions Of Interest and to reduce the processing time involved to a minimum. Therefore,
eliminating uninteresting image areas and those with poor information from the ROI means a
reduction of processing time.

Definition of the Regions Of Interest
Choose the first item from the “Pre-processing” menu to enter the section that is dedicated to the
definition and specification of the ROI. To determine a Region Of Interest it is necessary to mark
the area. Suitable graphic instruments are available to draw and colour the areas that are to be
analysed.
ROI identifies one or more areas within the sample-image where processing functions are executed
and where a specific rejection criteria is applied. If different rejection thresholds have to be applied
to specific areas on the sample-image, different ROI can be created and associated with areas that
have to comply with the same critical requirements.
The following example shows two areas within the sample-image that have to be examined and that
have different critical requirements. Two ROI have to be created, ROI 1 outlines the less critical
area , ROI 2 outlines a high critical area
ROI 1; less critial
ROI 2; high critical
A single ROI may include several areas within the sample-image.
ROI 2; consisting of two

different areas; defect ROI 1; consisting of a single
evaluation is the same for both area only
areas belonging to a single
ROI.
In this programming phase it is important to determine the areas of interest for the analysis and to
divide them into groups, according to their examination mode for possible defects, before the ROI
can be drawn. Two areas with the same critical level will be part of the same ROI even if they are
physically separate from each other.

Attention: The parts of the image that belong to one ROI cannot belong to any other ROI. The
outlined areas of ROI number `n´ are totally separate from all the other ROI. It will be shown in the
drawing phase how this principle is secretly performed by the system.
If two or more different ROI are included within

ROI 1 the same image part, this part belongs to the last
ROI that has been drawn; in the example to the left
the common area is part of ROI 1 because it has
been drawn after ROI 2.
ROI 2
Click on the item “Definition of Regions Of Interest” and a dialog box (see picture below) will
appear. It contains a variety of useful tools regarding the operation of drawing the constituting areas
of single ROI.
The following shows the standards that regulate the drawing of the ROI (physical definition):
Acceptability standard Name of the Sample

applied to the Sample.
Use this combo box control Use this combo box control
to select the standard from to select the ROI to be
the list: applied to the actual
Sample.
ROI list is updated any time

the acceptability standard is
changed.
Selected ROI areas are red-
coloured on the Sample
image.
Use this buttons to create, With this button, the actually

colour and delete ROI areas. displayed image can be saved
with actual colours.
Both command buttons
finish the operation but OK This button deletes the actual
confirms changes that may ROI. Confirmation required to
have been made. proceed.

The Line
A line is a basic element of the figures that can be created; it makes it possible to draw a polygon.
This command button activates polygon drawings on the image. Press the left mouse button
to fix the starting point (fig. 1); keep the mouse button down; move the pointer and
determine the other end of the line (fig. 2); release the mouse button; a line with two dots at
its ends will be drawn (fig. 3). The end point of the first line becomes the starting point for the next
and so forth.
Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5
To draw the following lines start from the end of the last created line, hold down the left mouse
button and move the pointer to the next required end (fig. 4); release the mouse button; the next line
is drawn (fig. 5). Repeat the operations shown in figure 4 and 5 to continue polygon creation.
Once clicked on the command button to draw section lines, this function will remain active until
another button is selected. This will be explained in the following pages.
The curve
A curve is a basic element of the figures that can be created; this makes it possible to draw circles,
ellipses and any other non-linear profile. Per disegnare una curva si utilizza il pulsante indicato. Si
This command button activates curve drawings on the image. Press left mouse button to fix
first curve point (fig. 1), release mouse button, move mouse to the next curve point, press
left mouse button, release mouse button, a line connecting first and second points is drawn
on the image (fig. 2), now move mouse on the line side where curve is supposed to develop, press
left mouse button, a curve appears (fig. 3), keep left mouse button down and move mouse until the
desired curve location is obtained, release mouse button to fix actual curve on the image.
The curved section drawn makes part of the polygon under construction.
Next polygon section will be another curve unless line button would be pressed.

The region
A series of polygon sections (lines and curves) becomes a region when it is closed. In addition, it is
useful (but not necessary) to avoid intersections of the section lines.
Fig. 1 Fig. 2 Fig. 3
Fig.1 shows a group of section lines still open, whereas in Fig.2 and Fig.3 the section lines are
contiguous and closed (the starting point of the first line and the end of the last line coincide). In
Fig.3 the section lines intersect each other. This will prove to be obviously dangerous and
counterproductive in defining the ROI.
Choose this command button to automatically close the actual polygon and create a region.
The final connecting section will have a line shape (fig. 1).
Mind that this closing line does not intersect the already existing section lines (fig.2).
Fig. 1 Fig. 2
When the operator finishes drawing, the end of the last line and the starting point of
the first one should be close to each other (see the picture to the left) to avoid
intersection (as shown in Fig.2 above).
Click on the command button to close the series of section lines shown in the
picture to the left. The result will be the region that you can see in the picture to
the right.
Only through the use of this command a region can be generated. At least two section lines are
necessary to generate a region by means of this command. With only one existing section line a
click on the command button will cause no effect.

Colouring
The next step to transform a region into a ROI or a part of a ROI is the colouring of this area. It now
becomes evident why a series of section lines has to be closed and without intersections – see the
following examples:
In this case it is not clear which one is the internal and which one the external part
of the possible ROI.
In this case the region is well defined and this will lead to a correct definition and
creation of a ROI.
In this case there are two possible parts of the region to be coloured; once
coloured one part, the other part remains empty.
Choose this command button to colour a region. Click on the button, move the pointer into
the required region, click again. The system will automatically fill the whole region with
colour. Thus a ROI or part of a ROI will be generated. The dots at the ends of the section lines will
disappear.
After having coloured a region, this region becomes part of the regions that define the ROI. Yet
they can be completely modified and even deleted or reorganized. These operations will be
illustrated later on.
The command button on the left combines the closing of a series of section lines and the
colouring of this region. By choosing this command the system will add the closing section
and a single click on the region’s inner part will add the colour to it. Click the right mouse button
with the pointer inside the region, and this operation will automatically be performed.
Sometimes it may be necessary to eliminate a part of a coloured region. A quick method is to

generate a region that cuts off the desired area (fig. 1).
Click on the command button to the left. Literally this function will take the “colour” off the
created region and thereby cut off the desired part from the coloured ROI (fig. 2).
Fig. 1 Fig. 2
The uncoloured region is treated as every other component of the ROI. Yet its function is to cancel,
not to colour. It can be modified as any other region.

ROI
Now we are able to define and construct closed regions, to colour them, to take the colour off again
and by combining one or more of these objects, it is possible to define a ROI.
Seen from the figurative point of view, a ROI is defined by the whole of the coloured regions,
except the regions where the colour has been removed, according to their order of creation. The
following example shows the creation of a ROI by means of successively defined regions:
The first two regions (reg1 and reg2) have been drawn and coloured,
another region (regA) is drawn between the two; the colour is taken off and thus cuts off parts of
reg1 and reg2,
a third coloured region is added (reg3), the uncoloured region (regA) will not
have any influence on the new region (reg3) because reg3 has been created
later than regA. The chronological order looks schematically as follows:
ROI = reg1 + reg2 - regA + reg3 .
This rule concerning the chronological order of the formation of a ROI remains valid if a single
ROI or more ROI are present that have no overlapping parts. But what happens if a ROI is defined
that overlaps another already existing ROI?
In this case the area belonging to several ROI will be assigned to the last ROI that has been drawn –
see the example below:
The first ROI is light grey, the

second dark grey and the third is
black; the result of the overlapping
of three ROI, according to their
chronological order, is shown in the
picture to the right.
Remember that all the regions that define a ROI affect only the ROI they belong to and not the
other. Consequently an uncoloured region will only eliminate the colour within the regions of its
own ROI.

Modifications
Choose this command button to delete the last section line or the whole region. Every mouse
click will delete a section line.
The starting point to create a new section line is always the starting point of the section line
just deleted.
Choose this command button to delete a whole selected region.
In both cases the deleted parts cannot be restored. Having made the modifications to a region
(additional changes or deletions) this region has to be closed, coloured or “uncoloured” as already
explained.
ROI selection
The system displays the ROI that have already been drawn (green) and the one that is just about to
be drawn (red) transparently. The index of the currently active and red ROI is displayed in the
textbox of the “Region selection” dialog box.
Use the scroll buttons close to the textbox containing the ROI index to scroll between the ROI;
every click moves one position up or down in the index, depending on the selected scroll button.
The selection of a different ROI will be followed by a colour shift: The former red ROI will become
green and the currently selected ROI will be displayed in red.
Visual Faris admits a maximum of 255 ROI per Sample.

Image alignment
A problem that arises during the working cycle is the correct and precise alignment of the casting so
that the resulting X-ray image will have the highest possible similarity, with respect to rotation and
translation parameters, to the image used to create the Sample.
Visual Faris does not require high mechanical precision concerning the casting position. It is able
to correct possible misalignment between the image that has been acquired on-line and the one
acquired during teaching procedure that is used as the Sample.
The alignment correction is carried out on the digital image and not by a mechanical re-positioning
of the casting. This considerably accelerates this operation up to almost real time speed.
Image alignment can be applied to every Sample but it is not always necessary. Image alignment is
essential if at least one of the following conditions is met:
• The alignment mechanism and fixing and/or transporting system for the casting do not
guarantee a precise alignment of the casting.
• Geometry and morphology of the casting are not uniform inside the image thus producing high-
contrast areas.
If the above-mentioned conditions are met, an appropriate alignment of the image is necessary, see
the following description:
There are four alignment functions customized for specific misalignment situations.
For most of these alignment functions a rectangular zone, called a “pattern” has to be found within
the image, through which the system will operate the alignment.

Roto-translational matching
This function has been developed to correct misalignment with both translational and rotational
component. This alignment method is based on the pattern matching approach.
Pattern should feature precise profiles, should be far from the image borders and should represent a
part of the casting that will not be subject to modifications.
Pattern rotation must not exceed -45° and +45°, compared to its original orientation on sample
image.
Roto-translational matching needs definition of two areas :
1. Reference pattern. This area should include unique image details that will not produce any
mismatch or aliasing under image rotation or translation.
Pattern outline is obtained in this way : move mouse pointer to the first rectangle corner,
press left mouse button and keep it down until mouse pointer is taken to the opposite
rectangle corner, then release mouse button.
Pattern rectangle is displayed with yellow-black colours.
2. Field of search. Pattern searching will be limited within an area that surrounds it. This area
has a rectangular shape and limits the zone where pattern will show up in the acquisition
image during castings inspection. Field of search dimension will effect time taken by this
function, it's recommended to size this rectangle to the minimum required by the
application. Field of search outline is obtained the same way taken with pattern, except that
the right mouse button has to be used instead of left one. The field of search rectangle is
displayed with continuous yellow colour. If search angle is equal to 0, field of search
drawing is disabled.
Field of search
Reference pattern

Verification window shows results of actual settings:

“Dimensions” shows dimensions of pattern rectangle;
allowed range for pattern size are between 32 and 256
pixels, furthermore, pattern rectangle must be totally
included by the field of search rectangle.
“Offset” shows the difference between the sample-image
and the acquisition-image in pixels; allowed range is less
than 0,2 pixels.
“Score” shows the percentage value of similarity
between the position of the sample-image and the
position of the acquisition-image; allowed range is over
99,0.
“Misalignment angle” shows angle of rotation of pattern
on acquisition-image compared to pattern on sample-
image; allowed range is less than 0,1.
“Search angle” this parameters sets the maximum angle
of rotation that the pattern may feature on acquisition-
image compared to the position on sample-image. This
value ranges from 0 to 90. With 0 no rotational search
will be performed. The greater the search angle aperture, the longer the time taken for calculations;
it's recommended to limit this value to the minimum required by the application.
Choose this button to confirm and save actual settings. If even one control item is not
checked, this button remains inactive.
Choose this button to exit the Roto-translational matching procedure without saving
actual settings.
Choose this button to reload data concerning the latest settings that has been successfully
saved.
Choose this button to erase all actual settings and disable Roto-translational matching.

Horizontal and vertical matching
In this case the casting can only move in one of the

following directions : horizontal or vertical.
In utilizing this feature, a rectangular area has to be
defined through which the system will be able to align the
whole image.
This area must satisfy the following requirements :
• Find and area with a uniform grey level (A).
• Rectangle start point have to be located within the
uniform area (point B or C).
• The uniform area has to be completely limited by one
of rectangle half; left or right in case of horizontal
alignment; top or bottom in case of vertical alignment.
• When rectangle has been completely drawn, the
uniform area is automatically blue coloured (D), if this
doesn’t happen, a new rectangle should be drawn.
• The uniform area has to be separated from the rest of the rectangle with a white line (E).
• The rectangle may have other uniform areas , but only the area where rectangle drawing started
is considered for matching process.
Every time a new rectangle is outlined, two control items evaluate if the reference zone is valid for
its purpose.
• “Dimension” shows if the rectangle sides have an acceptable size; allowed range is between
64x64 pixels and 400x400 pixels.
• “Score” shows the effectiveness of actual rectangle; allowed range is between 33,0 and 66,0.
D
A
E
B

Rotational matching for wheels

This alignment function is dedicated to wheels
application, in particular, for Samples taken on
wheel hubs from a top-down X-ray perspective. In
this case eventual misalignments have a rotational
component only.
The system needs the center of possible rotation to be
located as precisely as possible. Press left mouse
button as long as mouse pointer is taken to the wheel
center, then release mouse button. The system
performs an automatic wheel analysis looking for
actual wheel phase and orientation.
The wheel center location procedure is aided with
some circles that allow a better understanding of
center location. See picture on right.
In this case control items will be displayed:

• “Center” shows the coordinates where the center of
rotation is located; allowed values range between 1/3
of image size and 2/3 of image size.
• “Contrast” shows a figure of merit for actual image
contrast; allowed values are greater than 6.
• "Score" shows function effectiveness; allowed values
are greater than 5.
Choose this button to confirm and save actual settings. If even one control item is not
checked, this button remains inactive.
Choose this button to exit the Rotational matching for wheels procedure without saving
actual settings.
Choose this button to reload data concerning the latest settings that has been successfully
saved.
Choose this button to erase all actual settings and disable Rotational matching for wheels.

Remove details
The casting may have some “disturbing” details on its surface such as writing, bar-codes, labels,
stampings etc.; these details on the image may disturb the analysis of it. The centre of the character
“O”, for example, could be identified as porosity.
For these situations Visual Faris offers a set of functions that allows to compensate these side
effects.
Within a sample-image there may be several details that need

special processing to avoid false interpretation, and these
details may be located in different areas.
Specific removal operations can be applied to different areas
within the sample-image.
For each sample, up to 32 removal areas can be defined, see
"Area selection" list box on the left..
Each removal area can be associated with specific removal
parameters, see "Removal parameters" list boxes.
"Type" list box allows selection of removal function dedicated
to specific situations; the two list boxes below, shows
parameters settings related to the specific removal function
selected.
The following steps should be performed for any removal
operation :
• Definition of area borders
• Selection of specific removal function
• Selection of removal function parameters
Area borders can be outline with a polygon

composed by eight points.
Use mouse left button to fix each one of the
eight points. Area borders drawing can
continue until the desired shape is outlined.
Each point is green coloured except for the
next one that is about to be moved.
Once the area borders are defined, press mouse right button anywhere inside
the area to confirm actual drawing. Area just defined is now orange coloured.

Raised metal
This is the most common removal function. Its purpose is to level the
presence of surplus metal that may occur with the stamping of writings or
symbols on the casting surface. This function is associated with two
parameters "Level" and "Image".
Level is a figure of merit of how much surplus metal according to its
thickness has to be “removed”; larger and thicker details needs higher level
values. Available values range from 0 to 6.
Image is the index of the image this function will be applied to. This
situation happens when one sample is associated to more than one image
(see chapter Sample concept). If actual sample is associated to just one
image, this parameter do not have to be selected. If actual Sample is
associated to more images, this function can be applied to a specific image
within the images sequence, or , if no selection is made, to all images.
Image index ranges from 1 to 24.
Wheel rim : equalize

This function is specifically designed for Samples representative of wheel
rim. It is applied to all images a wheel rim is divided into.
Level is a figure of merit of how much surplus metal according to its
thickness has to be “removed".
If actual image shows darker areas compared with sample image, the
equalized image will show these areas with a grey level lower than the half
of grey levels scale. These areas can be clipped if a level not equal to zero
is applied.
Level 1 clips areas with a grey level lower than 10% of half grey scale,
level 2 clips areas with a grey level lower than 20% of half grey scale, etc..
Level ranges from 0 (no clipping) to 9.

ID box
This is a removal procedure exclusively dedicated to wheels, especially to
the stamping known as ID box.
This function enables the system to ignore indications located inside the
removal area associated to the ID box.
situation happens when one Sample is associated to more than one image
(see chapter Sample concept). If actual Sample is associated to just one
image, this parameter do not have to be selected. If the actual Sample is
associated to more images, this function can be applied to a specific image
within the images sequence, or, if no selection is made, to all images.
Image index ranges from 1 to 24.
Mould Junctions
This function has been developed to avoid false indications at mould

junctions location. Casting areas located at mould junction do have
variable shape and geometry caused by the casting process; for example,
flashes , thicker sections, etc..
To avoid that these indications would be interpreted as dark inclusion,
these areas can be identified as "Mould junctions", in this way any
indication classified as dark inclusion will be ignored, if located inside the
removal area associated with this removal function.
situation happens when one Sample is associated to more than one image
(see chapter Sample concept). If actual Sample is associated to just one
image, this parameter does not have to be selected. If the actual Sample is
associated with more images, this function can be applied to a specific
image within the images sequence, or, if no selection is made, to all
images. Image index ranges from 1 to 24.
A choice of command buttons is available to finish the operation: “Save” the recently outlined and
coloured area including the level of removal or “Read” the data concerning the selected area or
“Delete” the selected area and its data.

Gray Scale Extension
This function allows to expand the gray scale dynamic range of the acquired image.
This function is usefull when the image detector presents a significant decay in sensitivity and the
also the max x-ray power does not allow to reach a sufficient image brightness. Then You can use
this function to retrieve an mage brightness comparable to the origina situation.
This dialog box provides controls for the gray scale

extension.
“Activate extension” check box turns this function on
and off.
“Offset” controls image brightness. This parameter
ranges from 16 to max gray level value.
“Gain” controls image contrast. This parameter
ranges from 45 to 90.
The graphics show two profiles , blue profile
represents the sample image gray scale distribution,
orange profile represents the acquired image gray
level distribution.
Work on Offset and Gain in order to match the two

profiles as much as possible.
This function only applies to NTB or PerkinElmer image detectors

Enhance Details
This function allows the application of high pass filters to the pre-processed image.
These filters are designed to enhance all discontinuities as well as local variations in brightness of
the image, such as edges, borders and sharp geometries.
When using this filters, it may become necessary to exclude some high contrast areas from the
analysis, since those areas will be highlighted by the filter.
Filter 1 : light high pass filter designed for thin parts inspection, such as Die Casting parts.
Filter 2 : strong high pass filter designed for parts with a wide range of thicknesses
Filter 3 : filter designed for porosity check on pistons

Processing
The processing of the Samples represents the most important part of the programming. Processing
includes all the functions and the data that are used to identify defects on X-ray images.
1. Morphological processing.
A casting has a varied morphology; therefore, it is necessary that a variety of areas can be
defined. These areas will be called ROP (Regions Of Processing). ROP are areas where
defects can be inspected in a detailed and specific way. The ROP are part of the ROI that
have been previously drawn. We will call the group of parameters `search engine´ that
define the system’s way to search for defects within a selected and specified ROP. Up to
three search engines can be applied to each ROP. They will work simultaniously in the
specified area.
2. Foreign material processing.
Include functions for foreign material more dense analysis.
3. Custom processing.
Specific functions for particular applications.

Morphological processing
This programming session explores the concept of ROP.

With ROP, Region of Processing, we intend the association between a particular search engine and
an area in the sample image.
Choose this item from the programming menu and the following dialog box shows up. This window
allows ROP and relative parameters definition.
Sample name.
Use this button to display
the actual ROPs coverage.
Select the ROP and define

the search engine
parameters with the help
of this group of objects
With these commands the

ROP are modified, and the
processing results are verified
These parameters show

which anomalies have to
be considered defects (in
percentage compared to
the maximum grey value
of the image)

Up to 254 ROP can be defined for every Sample. It should be considered; however, that the more
ROP are used the more time is needed for processing. Therefore ROP should not be used in
excessive numbers.
Next to the “Show” button a textbox shows the index of the ROP that is currently displayed and in
progress. Click on “Show”: the whole area occupied by the currently selected ROP will be
displayed in red on the screen. Click on the scroll buttons to scroll the ROP. The caption
“occupied” alongside the scroll buttons makes clear that this index is referring to a drawn ROP,
whereas “free” means that the position is vacant.
Immediately below the index part there are three identical lines; each of them represents a search
engine:
Loads the latest data saved by

the search engine
Cancels the search engine data Displays the search engine results for the selected ROP
and disables it
A search engine is identified by a combination of two parameters, represented by the first and the
second edit box on the search engine row.
Every search engine will remain deactivated as long as the second parameter is 0. As soon as this
parameter will be higher than 0, the search engine will be activated.
The first parameter varies between 0 and 38. It is related to the image geometry and morphology
orientation..
The second parameter varies between 0 and 8. It is related to the maximum size of defects that the
system is supposed to look for.
The last parameter varies between 0 and 3. It shows the grade of inspection sensitivity that is
employed to examine the anomalies found during the analysis: 0 for max sensitivity, 3 for lowest
sensitivity. This parameter is also useful to eliminate false defects that can occur on-line.

Drawing the ROP
Automatic drawing
This is an example of a
sample with the ROI already
defined, see the green border,
and with no ROPs defined.
The automatic drawing method assumes the following steps :

• All ROI areas are assigned to a
sole ROP with a search engine that
best fit with the sample
morphology and geometry. Press
the Auto button, move the mouse
on the image, click on mouse left
button, then press the context
menu item that shows up. This
operation generates the first ROP
and assigns all ROI areas to it.
Now proceed with the search
engine selection that best fit with
the image.
• All residual areas that may not fit
with an engine are assigned to
other ROPs which hold different
search engines. Move to the next
free ROP index, press the Auto
button, the displayed image shows
the effect of the first ROP search
engine, bright areas correspond to
those areas that do not fit with the
first ROP search engine.

• Move mouse around the image, when mouse pointer passes over a bright area, the latter
automatically changes to red color.
• press mouse right button
and the following context
menu shows up :
The first context menu item allows to assign the red areas to the actual ROP.
The second context menu item allows to remove the red areas from the actual ROP.
Manual drawing.
To manually draw a ROP, first press the “Man” button.
Use mouse left button to fix the vertexes of the polygon that outlines the ROP
area about to be designed. Then get inside the polygon and press mouse right
button to fix the ROP area.
All the parts of the polygon drawn outside the ROI will automatically be
clipped.

General parameters
“General parameters” supply three parameters that are valid for every ROP:
The first two determine which imperfections have to be considered as real defects. This will be
assessed according to their grey level in relation to their surroundings.
“Upper threshold” refers to the percentage of grey levels within grey level range.
“Lower threshold“ refers to the percentage of grey levels within grey level range.
Upper threshold establishes the upper limit for the presence of a defect. Lower threshold
establishes the lower limit where a defect is mistaken for surface roughness or background noise.
Click on the appropriate command buttons to vary these parameters. The Upper threshold can vary
from 1% to 100%, whereas the Lower threshold can vary between 0% and the upper threshold’s
current value.
The example below shows the Lower threshold as a dashed line and the Upper threshold as a
dotted line. The chart shows the course of an X-ray image line. Several anomalies, more or less
strong, can be noticed.
The next figure shows the same line, after the Upper and Lower threshold have been applied.
Only the anomalies that cross the Upper threshold are considered. The depth of the defect is
evaluated to the Lower threshold.
“Compensation” is used for a better absorption linearity of the X-rays. X-ray absorption is
distorted by a material’s thickness variety so that two defects of the same depth but located in
different areas may seem different on the X-ray image. The system compensates for these
distortions by means of this parameter.

Foreign material processing
These functions allow detection of indications with higher density than the casting material such as
iron or steel objects into an aluminium casting.
Notes
These functions are applied to the acquired image; that is to say that eventual
remove detail functions does not have any effect on foreign material functions. Remove
details functions also work on the acquired image, but have their results on the pre-
processed image.
Restrictions
These algorithms work on local unexpected variations of the grey levels. These variations
may be originated by presence of foreign material that is denser as the material of the same
type of the casting. The latter case happens with machining residuals, flashes, chips, or other
material that may stay on the casting before entering the X-ray unit. There is no way to
distinguish the former and the latter cases, as they both show up as a local unexpected darker
spot on the acquired image. It is recommended to clean the casting before the X-ray
inspection to avoid false indications.

High density inclusion
This function has been developed to detect presence of dark inclusions with significantly higher
density compared to the casting metal.
Select this function from the top menu and the image and dialog box shown below will appear.
The image shows the sample and areas blue or yellow coloured. The blue coloured areas are those
areas not included in the ROI, the yellow areas are those areas that contain edges or high contrast
features or sharp variations of the grey levels.
Both blue and yellow areas cannot be analyzed with this function. Inclusion search will not be
performed in these coloured areas.
Virtual inclusions can be applied with the proper button from

the sample toolbar. Simply click on this button and move the
virtual inclusion around the image. Use right mouse button to
change the inclusion size, and left mouse button to freeze the inclusion
on the image.
You can use also mouse wheel to change the inclusion density.

Check this button to activate the “High density inclusion” .
This parameter represents the minimum relative density of the

inclusion to look for. The inclusion appears as a darker spot
within the sample image in contrast to the area where the brightness is supposed to be brighter. This
parameter is a threshold of the variation in brightness (darkness). The indication is rated as an
inclusion if its darkness exceeds this threshold.
This image has added three virtual inclusions of the same

dimension and different darkness. In particular, the inclusion in
the middle has half the density of the top inclusion and the
inclusion on the bottom is four times less dark than the top
inclusion.
The following three images show the results of the “High density
inclusion” function with three different threshold values.
The higher the threshold , the darker the inclusion detected.
To detect inclusion with lighter darkness, we have to lower the
threshold.
At very low threshold values, dark areas of the sample image may
be considered as dark inclusion.
Caution must be taken on selecting low threshold values in order to avoid false indications caused
by dark sample areas.
This function is optimized for detection of dark inclusions with significant higher density compared
to the casting metal.
Thin, flat, low contrast and shallow inclusions, are not included in the scope of this function.
threshold = 21 threshold = 15 threshold = 5

Medium-high density inclusions
This function has been developed to detect presence of dark inclusions with higher density
compared to the casting metal.
Select this function from the top menu, and the image and dialog box, shown below, will appear.
The image shows the sample and areas blue or yellow coloured. The blue coloured areas are those
areas not included in the ROI. The yellow areas are those areas that contain edges or high contrast
features or sharp variations of the gray levels.
Both blue and yellow areas cannot be analyzed with this function, thus, inclusion search will not be
operated in these coloured areas.
Virtual inclusions can be applied with the proper button from

the sample toolbar. Simply click on this button and move the
virtual inclusion around the image. Use right mouse button to
change the inclusion size and left mouse button to freeze the inclusion
on the image.
You can use also mouse wheel to change the inclusion density.

Check this button to activate the “Medium-High density

inclusion” .
This parameter represents the minimum relative density of the

inclusion to look for. The inclusion appears as a darker spot
within the sample image in contrast to the area where the brightness is supposed to be brighter. This
parameter is a threshold of the variation in brightness (darkness); the indication is rated as inclusion
if its darkness exceeds this threshold.
Differences between “High density” and “Medium-High density” inclusion functions:
• Processing time. “Medium-High density” takes more time that “High density” . If we take
the images used in the previews pages, as an example, “High density” takes about 30ms,
while “Medium-High density2 takes about 250ms.
• Sensitivity. “Medium-High density is more sensitive than “High density”. That is, the
former can detect lighter inclusion than the latter. Here is an example of what happens if we
apply each function to the same image with four inclusions. Each one is half as dark than
the next from a top to down sequence. The image on the left is processed with a “High
density” function, threshold 8 is the minimum value that allows inclusion detection and
avoids false indications to appear. Consequently, a lower threshold will detect also false
indications. With this setting, only three inclusions can be detected. The lighter one is
missed. The image on the right is processed with a “Medium-High density” function.
Threshold 33 is the minimum value that allows inclusion detection and avoids false
indications to appear. A lower threshold will detect also false indications. Additionally,
with this setting the fourth inclusion can be detected.

Post-processing
Choose this properties sheet to establish some parameters

that will be used after the system has identified the
defects.
“Close internal points” will fill small spaces inside the

defects that have not been identified as defects
themselves.
“Delete single points” will ignore defects of the size of

one pixel or less.
“Delete single lines” will ignore defects of the size of

one pixel or less that develop linearly.
“Link defects (pixels) ” will join together defects that are

particularly close to each other so that their distance is
less than the entered number. Unit is in pixels.
“Link defects (min diameter)”. This is used if the distance between two adjacent defects is smaller
than the length of the smaller of the two defects, both defects are connected together , see pictures
below.
These operations are executed in the order of their appearance in the dialog box. Click on “Exit” to
save the parameters concerning the Sample and to close the dialog box.

Results interpretation
In this stage all the necessary parameters are defined to classify the correct defect dimension and
casting acceptability.

Regions of magnification definition

As previously mentioned, it is necessary to know the factors of the spatial magnification
arrangement in order to ascertain the dimension of the verified defects with maximum precision.
There are a variety of procedures depending on the complexity of the casting to assess the
magnification factors for the different Sample image areas.
If the casting geometry is uniform and if the distance between the casting and the X-ray source and
the image intensifier is constant for every part of the casting within the Sample image, it is
possible to establish a single magnification factor for the entire Sample image. In this case there
would be only one ROM (Regions Of Magnification) with a certain magnification factor. Measure
the size of a detail (in pixels) that can be identified on the Sample image to calculate this factor.
The magnification factor equals the relations between the length in pixels and the length in the
chosen measure.
If the casting geometry is not uniform, the Sample image has to be divided into as many areas as
there are local uniformities. The assessment of the magnification factors for each of these areas will
be described in the following pages.
-- Complete the programming of all the Samples that are relevant for the casting in
examination. Leave the definition of the ROM and of the relative magnification factors
pending.
-- Look for another casting without defects but not the casting used for the Sample acquisition.
At this point, having carried out the Sample programming, the search for a defect free
casting can be performed using the system manually or on-line.
-- Apply artificial defects to this defect free casting within the Regions Of Interest (ROI) of
every Sample.
To minimize calculation errors concerning the magnification factor these artificial defects
must have the following characteristics:
Form: spherical.
Dimension: minimum diameter of the artificial defects: 10 pixels – in order to
reduce statistical errors. In reality, as the magnification factor is still
unknown, it is not possible to know how big (in inches, mm, or other)
the defect must be to be equivalent with 10 pixels in the image.
Normally the optical magnification varies from 1:2 to 1:1; with an
intensifier of 9 inches and a digital image of 768x576 pixels. You
need to impose defects approximately between 2 and 4 mm to obtain a
defect image of approximately 10 pixels. The closer the casting is to
the intensifier the bigger the defects must be. It is necessary to
measure both sizes of the artificial defect (in pixels and its physical
size). On the basis of these measures the magnification factor will be
obtained and it will be linked to the area that surrounds the defect
creating a ROM.
The higher the number of artificial defects that have been created, the
more detailed the map of the magnification factors and, consequently,

the more precise the assessment of the real defects. The only real
disadvantage of creating many ROM consists in the time the
programmer has to spend on creating, measuring, calculating the
factors, and drawing the ROM. The number of ROM will not affect
the period necessary for the analysis; whether there is only 1 or 255
is irrelevant.
-- The casting with the artificial defects will then be exposed to the manual inspection cycle.
Load the Sample corresponding to the first view of the inspection.
Choose Image acquisition to acquire an image when the casting arrives at the first inspection
view.
Choose Execution to create the Sample of the acquired image.
It is now necessary to check if the results correspond to those anticipated. The ascertained
defects must correspond to the artificially created defects. The artificial defects must be
similar in shape to the real defects that are known. If this is not the case, the programming
data needs to be accordingly modified.
Choose the item Programming to modify the data of the current sample. Proceed as it is
described in the chapter Sample programming. Intervene only where necessary. Choose
Execution to check the effectiveness of the modifications that may have been made. Control
the processing results on the image monitor. Save the selected Sample to store the
modifications being made.
-- Finish the possible adjustment of the program. Select Display statistical defect information
from the toolbar to perform the Sample and to get a table that displays the characteristics of
every single defect. The unit of measurement for the defect area is pixel squared. The
magnification factor is calculated from the square root of the ratio of this parameter divided
by the chosen measurement unit. This magnification factor has to be established for every
defect area.
-- Once the magnification factor has been calculated for every sample defect, proceed with the
definition of the Regions Of Magnification (ROM) as indicated on the following page.
-- The number of practicable artificial defects depends on the geometry of the casting. The
larger the number of sample defects, the more precise the definition of the ROM but it will
take much longer. Additionally, it will be more complicated to obtain the magnification
factors and to draw the ROM.

Formula for the calculation of the magnification factor
To calculate the magnification factor Fm to formulas are used:
The first one is the measure of a detail in pixels divided by the accordingly chosen unit of
measurement (e.g. mm)
Dimension px
Dimensionpixel
Fm =
Dimensionmm
Dimension mm
It is also possible to calculate the magnification factor by extracting the square root of the detail
area in pixels and dividing it by the according area measured with the chosen unit of measurement
(e.g. mm).
Area px Area mm
Area pixel 2
Fm =
Areamm2
It is possible to establish up to 255 different areas of magnification (ROM) with Visual Faris.
The areas are numbered from 1 to 255 and each area has its own magnification factor.

Choose the item Definition of Magnification Regions to display the currently established ROM.
The image will show the currently selected ROM in yellow and the areas that belong to other ROM
in blue. The ROM properties sheet can be found to the right of the image.
Drawing a ROM is the same kind of procedure as drawing a ROI; the graphic tools are the same.
Sample name
ROM index and scroll

buttons
Magnification factor
Buttons for drawing and

ROM area management
Measure selection
With this button, the actually displayed image can

be saved with actual colours. Save file dialog box is
automatically displayed
Exit and confirmation

buttons

Use one of the above-mentioned methods to introduce the magnification factor. It is also possible to
introduce this factor semi-automatically by using the measurement section. Click on the
measurement command button to calculate the magnification factor, Place the pointer on a known
detail on the image, and then click on the starting point of the measurement. Hold down the left
mouse button and move the pointer to the end of the detail. The size for the measurement (in pixels)
will be displayed in the measurement box. Insert manually the measure corresponding to the detail
in the chosen measurement unit in the textbox “Unit”. The corresponding value will appear in the
magnification factor box.
The magnification factor is a floating point that ranges from 0.0001 to 9999.9999; the precision is
given up to the fifth decimal figure, e.g. 12.12345. The magnification factor corresponds to the
conversion factor from pixels to the chosen measure (mm, inches, etc.), for example: a factor of 4.5
means that 4.5 pixels correspond to a unit in mm, inches, or other.
Choose the OK button to confirm the modifications made concerning the definition of the ROM.

Standards definition
This function opens a program that organizes the definition of acceptability standards that are to be
used for the assessment of the inspected castings.
Each time this program is closed, Visual Faris will load the established data and immediate
control of the data is possible.

Rejection statistics
Choose this item from the menu or from the X button

from Defects statistics property sheet to open a
dialog box that displays results of the analysis of
acquisition-image.
Reset inspection results
Choose this item from the menu to reset all results relative to all open samples and working
program.

Regions Of Belonging
This is an optional functionality developed to manage multiple parts inspections.

Different parts can be simultaneously inspected with the same working program.
Working program samples can contain different portions of different castings, each casting portion
can be individually analyzed with proper processing parameters (ROP, ROM, and ROI).
The acceptability standard must be the same for all castings belonging to the same working
program.
Programming
ROB areas have to be programmed for each Sample. That is to say that within each Sample
the portions of different castings have to be identified and associated with the proper ROB
identification number. The system assumes that during inspection, each casting has to be
located in the same position and each casting position must have a specific and unique
identification number (ROB index). As a state of the art processing software, Visual Faris
handles up to 15 different castings per working program. That is, 15 different ROB with
indexes from 1 to 15. ROB index must be linked to the casting position number.
ROB definition works the same way as ROI or ROM.
Within sample-image, multiple castings may appear; areas belonging to the same casting shall
be outlined and assigned to a specific ROB with index equal to the casting position number.
Processing
Defects statistics window has a new “property page” labelled as ROB.
Defect ROB index
The progressive number of the casting that

contain the actual defect.
This number is saved in field “Progressive” of
database ProductionReport.mdb.
This field indicates the acceptability report for

actual sample. This is not the overall
acceptability of the actual sample, only defects
that belong to the casting of the actual sample
are taken into account, in other words, the
acceptability report shown in this field does
refer to the ROB areas of the actual defect.
This field lists the ROBs present in the working

program.
Should a defect be located in an area without

castings, the following message will appear:

Execution
On an Inspection cycle in progress, the results of images, samples, and castings will be displayed
using the same window for single-part-inspection and multi-part-inspection.
Case of single part inspection.

Results are displayed in three boxes: actual image, actual
view and actual casting.
Green box means accepted; red box means rejected.
Case of multi parts inspection.

Results are displayed in three boxes: actual image, actual
view and actual casting.
Each box will have as many stripes as the number of
castings that make part of the working program.
Green stripe means part present and accepted, red stripe means part present and rejected, grey
stripe means part absent.
Informations saved in ProductionReport database
Table Field Casting Acquisition Casting Casting rejected

absent failure accepted
TCastings Accepted true false true false
Inspection false true true true
Executed
Inspection ABSENT NOTEST ACCEPTED REJECTED
Report
Table Field Casting Acquisition Sample Sample rejected
Tviews Accepted true false true false
Table Field Casting Acquisition Image Image rejected
TImages Accepted True False True False
ErrorCode 0 1000 0 Xxx
ErrorMessage “” “acquisition “” “error message”
failure”
Progressive fields of all ProductionReport database tables will be updated on the basis of the
number of parts included in the working program, regardless of whether or not some of the parts are
absent during the inspection.
Counters shown in the inspection in progress window take into account only parts present during
the inspection.

Regions of rejection coding (RejectionCodingAreas)
This functionality is optional.

Specific rejection codes and messages can be associated with user-definable sample areas labelled
henceforth as RCA.
Whenever a non-acceptable defect shows up in a particular sample area, the rejection code and
message associated with the area where defect lies can be eventually notified to the production line.
RCAs are independent from all other sample mapping: ROI, ROM, ROP, ROB, etc..
The RCA index represents the rejection code associated

with the RCA area. This number ranges from 1 to 255.
The message associated with the actual RCA can be

entered in this edit box; Virtual keyboard available.
RCA area drawing works the same way as ROI, ROM,

ROB, etc....

Defect statistics
Click this icon from Sample toolbar to open a properties sheet that displays the data regarding
every defect that has been found after the processing of the acquisition-image. The displayed data
refers to the defect that is currently coloured and surrounded by a square. Use the scroll buttons
next to the defect number to scroll from one defect to the next. Defect information is split into three
property pages that group homogeneous data .

Programming functions toolbar
For faster access to main programming functions, a proper toolbar has been added to each sample.
This toolbar will appear only for monitor resolutions greater or equal to 1280x1024 :
ACQ : Acquisition Controls

ROI : Regions Of Interest
MRT : Roto.Translational matching
MH : Horizontal matching
MV : Vertical matching
MR : Rotational matching for wheels
RD : Remove Details
ROP : Regions Of Processing
ROM : Regions Of Magnification
In case of applications for pistons analysis, the programming toolbar provides access to the custom
functionalities specifically developed for this task.

Programming flow chart
The following flow chart describes the operations sequence from acquisition to acceptance .
Image Acquisition
Initial image in ACQ Buffer
Final image in ACQ buffer
Parameters : Integration frames , MultiEnergy steps, MultiEnergy decrement
Under light
Check Brightness Flickering
Matching ROB_AlignmentChe check check
Calculate acquired image
average brightness within the Calculate acquired
ck Calculate acquired
ROI. Calculate acquired
image misalignments image average image flickering level
Succeeded if : Succeeded if : Calculate ROB misalignments brightness within the within the ROI
•Acquired image average •X and Y shift are in Succeeded if : ROI Succeeded if :
brightness is higher than the range set in •ROB alignment is the range set in Succeeded if :
•Flickering level is
(max_gray_level / 16) acquisition controls ROB controls •average brightness is the range set in
• Acquired image average the range set in acquisition controls
brightness is more than 50% acquisition controls
lower than the sample image
average brightness
Acquistion controls
NOTEST OK
Part is classified as NOTEST Inspection proceeds
and inspection ends
Image pre-processing
Initial image in ACQ Buffer
final image in PRE buffer
Remove details
Smoothing
ROI masking

….. from preprocessing
Image processing
Initial image in PRE Buffer
Final image in BIN buffer
High dense inclusion search
Custom processing
ROP search
Binarization
• Compensation , High threshold, Low threshold
Saturation controls
Post processing
Initial image in BIN Buffer
final image in BIN buffer
Post processing sequence

Close inner points, remove single lines, and remove single points, link
defects
Results interpretation
Initial image in BIN Buffer
final image in RES buffer
Evaluate defects features in pixels
ROM: Convert features in physical unit
Determine
PASS acceptability
FAIL

On-line inspection
Visual Faris will be automatically configured as a part of the system when the system is started.
Visual Faris is then ready for external command control such as the CNC of the X-ray system, for
example, and to acquire, analyze and interpret the images coming from the on-line inspection of the
casting. The following screen is displayed during on-line inspection.
Working program
under inspection
Sample index
Image index
Number of castings
currently inspected,
and the number of
castings rejected
The second edit box on the bottom displays five data: The first one shows the
difference (as an absolute value) between the average grey level of the current
image and the average grey level of the reference image of the Sample. It is,
therefore, an indicator for brightness changes. The second and third data points
state the horizontal and vertical misalignment between the current image and
the Sample image in pixels. The fourth data states the eventual rotational
misalignment. In the case of Rotational matching for wheels, the data is
expressed in radiants. The fifth data states the rotational misalignment in case of
roto-translational matching; expressed in degrees.
The first edit box on the

bottom shows the actual
operation in progress.
Click on this button to exit from inspection in progress window and login to programming
window.
Click on this button to move from programming window to inspection in progress

window.

These three boxes show inspection results per actual

image, actual view and actual casting.
A green check mark stands for OK , while, a red check
mark stands for rejected.
Production counters
Click on this button to reset counters.
The Counters manager window will appear.

The operator can enter his name, press Reset button
to clear controlled and rejected counters or press OK
to exit.
Click on this button to display the Production

counters window.
This window lists the working programs executed from the
last counters reset, in terms of inspected parts and rejected
parts.

Production images viewer
Click on this button to open the last cycle images gallery manager. Images of the last
executed cycle are collected into a temporary memory and can be reviewed at any time by
pressing this button.
The two rows of pseudo led represents each one of the stored images. Green leds are associated
with images that do comply with the acceptability standard, red leds are associated with images that
do not. Grey leds do not have images saved. The system allows the storage of up to 64 images per
cycle. Images are automatically reset at the beginning of the next cycle.
Images can be displayed by pressing the led buttons or by pressing these buttons :
Use this button to close the image gallery window.

Production statistics
Visual Faris provides the ability to store the entire information
regarding inspected castings as well as all data regarding the
ascertained defects in a Microsoft Access® database file names as
"ProductionReport.mdb". This database manages the following
four tables:
Field Type Description

Progressive Number Progressive number for inspected castings
Date Date/Time Date and time when the current progressive had been inspected
WorkingProgram Number Working program code
WorkingProgramName Text Working program name
TotalViewNumber Number Number of views in the current working program
Accepted Boolean Inspection report for the current progressive : True=good, FALSE=reject
InspectorName Text Name of the indivisual or machine who made the inspection
InspectorCode Number Code of the indivisual or machine who made the inspection
Shift Number Shift when the current progressive had been inspected
Customer Text Customer for the current progressive
Stock Text Stock for the current progressive
Year Number Year when the current progressive had been inspected
Month Number Month when the current progressive had been inspected
Day Number Day when the current progressive had been inspected
PartNumber Text Part number of the current progressive
SerialNumber Text Serial number of the current progressive
CycleTime Number Cycle time taken for the current progressive
LoadingTime Number Loading time (idle) for the current progressive
InspectionExecuted Boolean True if current progressive had been inspected
InspectionReport Text Desctiption of inspection results
Mold Text Mold utilized for the current progressive
Date06to06 Date/time Date and time in the 06AM to 06AM timeframe
ForcedReport Text Set in case results being modified by the operator
PalletCode Number Pallet code for the current progressive
HeatTreatRackCode Text Heat treat rack code for the current progressive
HeatTreatRackIndex Number Heat treat rack index for the current progressive

TCastings table includes data of a single casting.
TViews table includes data of all samples that constitute part of castings
inspection sequence.
TImages table includes data of all images that constitute part of each
sample.
TDefects table includes data of all defects found


Settings
Use the following dialog box to register the method, in which statistical data is to be saved.
Production statistics options.

The first block of information refers to the ProductionReport database file.
Database file location can be selected with the “Folder” edit box, either manually or with the
“Search” button.
Database file backup location can be selected with the “Backup folder” edit box, either manually or
with the “Search” button. ProductionReport database backup is automatically executed when file
size exceeds 900 MBytes, or, it can be manually executed from the top menu :
“Production statistics \ Save ProductionReport on ...”.
ProductionReport file will be saved with the following name:
ACRE 280 03.02 18-04-2003 15.13.32 21020 32786.mdb
Last progressive number
First progressive number
Hour.minute.second
Day-month-year
Machine type and serial number

Save bad images options.
The second information block makes it possible to enable the saving of all images that resulted in a
casting rejection, to a directory chosen by the user.
Images are stored in software created folders using a structure as indicated below:
New folders are automatically created every hour.
Images file name is as follows :
“15.13.2P41672W13V2I1A0S0M4N1642”
1 Time file is saved

2 Casting progressive number with prefix P
3 Working program code with prefix W
4 Sample number with prefix V
5 Image number with prefix I
6 Inspection result (0=good, 1=bad) with prefix A
7 Casting serial number with prefix S
8 Mold serial number with prefix M
9 Working program name with prefix N
File name extensions depend on the images format selected from the options dialog box.

Inspection result with prefix A coding
BHT standards
A0 : passed image
A1 : rejected image because defect diameter over threshold
A2 : rejected image because defect area over threshold
A3 : rejected image because defect diameter and area over threshold
A4 : rejected image because defects density over threshold
A5 : rejected image because defects diameter and density over threshold
A6 : rejected image because defects area and density over threshold
A7 : rejected image because defects diameter and area and density over threshold
A8 : none
A9 : none
A10 : none
A11 : none
A12 : none
A13 : none
A14 : none
A15 : none
A16 : rejected image because defects number over threshold
A17 : rejected image because defects diameter and number over threshold
A18 : rejected image because defects area and number over threshold
A19 : rejected image because defects diameter and area and number over threshold
A20 : rejected image because defects density and number over threshold
A21 : rejected image because defects diameter and density and number over threshold
A22 : rejected image because defects area and density and number over threshold
A23 : rejected image because defects diameter and area and density and number over threshold

Save inspection images options.
The second information block makes it possible to enable the saving of all images to a directory
chosen by the user.
Images name and folder structure is the same as bad images

Reset ProductionReport
This option allows the user to empty the ProductionReport.mdb file. Prior to emptying this file , a
copy of the same is made on a file named "ProductionReport_old.mdb".
Production viewer
This option opens a dialog box that allows a user to display most significant information stored in
the ProductionReport database.
Production explorer
Production explorer is an optional software product, not included in the default Visual Faris
package that allows a user to fully explore and navigate within the ProductionReport database.
Compact database
This function compresses the database as much as possible. It considerably reduces the database
dimension if the data of all detected defects is to be stored. This operation may take several
minutes in the case of a large database size.

DIAGNOSTICS
Image quality
Select this function to control the quality of the image that the system is able to acquire. The
following dialog box will open and the system will automatically change into on-line acquisition.
This part of the dialog box

displays a time variation
graph concerning the
correlation between signal
and signal noise; the higher
this value the less trouble
The second graph displays concerning the image. Below
the course of the stability the graph, two textboxes
variations of the image; the show the instantaneous and
lower this value the better the the average value.
image quality. Below the
graph two textboxes show
the instantaneous and the This graph displays the
maximum value that has image histogram. In the
been recorded. textbox below the average
grey level of the image is
shown.

Camera alignment
This is a machine setup procedure that has to be performed by BHT technicians or other authorized
representatives.
Optical chain sensitivity

This is a machine setup procedure that has to be performed by BHT technicians or other authorized
representatives.
Compare sample and actual image

Choose this function to check visually and numerically alignment variations that the system detects
concerning the Sample image and the image currently acquired.
The screen is
divided into four
squares: The first
two upper squares
contain the
Sample image and
the image that has
been acquired in
real-time. The
latter is the image
for the
comparison. The
image on bottom
left shows the
grey differences
(subtraction of the
image) between
the current image
and the Sample.
The image on the
bottom right
shows the opposite, or rather the difference between the Sample and the current image.
The properties box alongside contains the data with reference to the luminosity variations (average
grey levels) in the areas defined within the ROI, misalignments along the X and Y axes regarding
the chosen alignment for the Sample and possible rotation angle variations if a rotational alignment
was chosen.

Monitor
This item has a cascading menu
including six items. It is possible
to choose and display geometrical
figures on the whole screen to
examine the functioning and the
correct response of the monitor by
an optical test.

Contrast sensitivity
If the X-ray machine performs a
self-calibration procedure using a
step-wedge with calibrated
sample defects, every
measurement on every sample
defect of the step wedge is
collected into a database.
This database can be explored to
see the behaviour of the imaging
chain since the installation.
Select the item "Statistics of the

measures on step-wedge" from
the "Diagnostic \ Contrast
sensitivity " menu.
The side window will appear.
The upper group box shows
information about the step wedge.
The central group box shows
information about every single
sample defect.

View
Choose the item “View” from top menu to find a list of all currently open Samples. Select one
Sample to place its window in the foreground.
Display classification palette for reference defects

Choose this item to display a small box that shows the relation between the colours and
the levels of classifications for reference defects.
Level 0 (black) signifies that the detected defect features are below the values of level 1
of reference defects.

About boxes
Visual Faris
System
This window displays generic information about Visual Faris that is useful for Bosello’s
technicians. If required, problems can be diagnosed.
Actual sample
This page contains all the information about the currently active Sample:
The machine code identifies

the FARIS system in the case
of several FARIS programs
within the same system; the These are all the
creation code tells if the details regarding the
Sample has been created on dimensions in pixels
this system. and in grey levels of
the Sample.
Dates and hours of creation,

access, modification and
saving of the Sample.

Working program
A window displays the name of the Working program that is currently open and the number of
the Samples contained in this program.
Resources
A window will display the number of Samples that can be loaded into working memory and the
number of those that can be stored on the devices available on the PC.
Visual Faris has two types of memory: RAM (random access memory) and permanent memory
for example on Hard Disk, Floppy Disk, etc.
The system uses RAM while operating, e.g. while programming or processing. The permanent
memory facilities are used to store Samples.
Selecting the item "Resources" from the "About boxes" menu will open the following window that
shows the number of Samples that can be loaded into working memory (RAM) and the number of
those that can be stored on the devices available on the PC
Disks and devices shown in this window may not correspond to the real PC configuration as the
latter depends on the particular application.

System utilities
Languages
Visual Faris user interface language can be changed on line from the “Languages”
top menu item.
As a state of the art software, Visual Faris can handle the following languages :
Virtual keyboard
Virtual keyboard allows to type characters and numbers into edit boxes.
Next to the keyboard name, the title bar displays the name of the window to which the keyboard is
connected. Hence the typed data will only affect the calling window edit boxes.
A text display is placed in the upper part of the virtual keyboard showing typed chars..
Each button works the same way as a normal keyboard with the exception of SHIFT
button , that remains active until it is clicked on again.
To move from one edit box to another use the TAB key ; this function will run through the
textboxes according to their input order, use SHIFT button to move backward.
When the data input is finished, click on EXIT button at the right bottom of the keyboard.

Userr Manual
Choose this item to display Visual Faris instruction manual whenever it is necessary. The
following window will appear:
Visual Faris user manual will be

displayed on the screen.
“Scroll” through the various pages of the
manual using the scroll bar or the scroll
wheel of the mouse. If the page number in
the table of contents is clicked on, the
corresponding page will immediately be
displayed.

User policy
With User policy , a hierarchy user’s structure is established to sort single functions accessibility.
This process ensures that only valid users gain access to resources and functions on Visual Faris.
Each registered user has a unique name, a personal secret code, and access level.
Access levels range from 1 (low level) to 8 (high level). Each level gives access to specific
functions and operations.
Visual Faris provides three levels of accessibility; see table at following pages.
With User policy , at system start-up, top menu is automatically disabled and “Visual Faris
inspection in progress” window is displayed.
To close “Visual Faris inspection in progress” window and get into the programming window,
press the user button on the top-right corner.

User Registration.
To gain access to Visual Faris functionalities, a user needs a user account. A user account
contains information about a user
User registration procedure has to be performed to introduce new users to Visual Faris
functionalities. This procedure can be only operated by users already registered and with proper
level.
The registration dialog box provides fields for new user identification.
Confirm Virtual keyboard Cancel
Name. Each User is identified with a name. A user name cannot be shared with other users. If the
entered name already constitutes part of users list, the system will display an error message.
Password. Each User has a personal security code for logon operations. Passwords have to be
entered twice. If entered passwords are void or not equal, the system will display an error message.
Access level. This level determines the user accessibility to Visual Faris functionalities. Levels
range from 1 to 8, but the available range can be reduced depending on the application where User
policy is adopted. Visual Faris only has three levels.
Press this button to complete new user registration.
Press this button to display virtual keyboard and type characters using mouse.
Press this button to abort new user registration.
User registration procedure can be activated from the top menu with Add new user function :

Logon
Logon procedure is requested to exit “Visual Faris inspection in progress” window and access
programming functionalities. Press the user button on the top-right corner.
Logon process provides the user with access to the level which the user has been assigned the
appropriate permission.
Type a user name and
password in the appropriate
areas, then press confirmation
button to initiate logon
process, or cancel button to
abort.
Confirmation Cancel
Logoff
Logoff procedure is requested to exit programming window and access “Visual Faris inspection in
progress” window. Press this icon to perform logoff procedure.
Show users list

This function shows data
about registered users.
Name list-box allows to scroll Registered users list
all registered users.

If the actual connected user
has the maximum allowed
level, he can modify other
users level end eventually
remove users from the
registered users list.
Users list can be accessed
from the top menu as follows:
This button calls the New

User Registration dialog
Use this button to erase the

selected user

Show connected user data

After logon, the connected user can take a look at his
account by pressing left mouse button on this window.
Usually this window is located at the top right corner
of Visual Faris application window.
This dialog box shows

connected user account.
Press confirmation button to
exit.
Users actions traceability

Most significant actions operated by registered users are collected and documented into a database
to keep track of Samples and Working programs modifications.
User action traceability can be activated from top menu as shown in the
side picture. Only users with a level equal to the maximum allowed
level (3 on Visual Faris) can operate this activation or deactivation,
other users will see this function disabled .
When user action traceability is activated, any time a Sample or a Working program are saved,
the system automatically shows a dialog box asking for some comments to be entered about actions
taken by the connected user. Comments can be as long as 255 characters.

Show actions.
Registered users actions, collected as long as traceability has been activated, can be displayed with
a proper dialog box that shows actions data and description.
Cancel actions
If an actual connected user has the maximum allowed level, he can cancel individual user action
list.
Users action list can be accessed from the top menu as follows:
Enable easy logon

To speed up sample programming and Working program fine tuning, logon process can he
temporarily disabled and free access and escape from programming and production window can be
performed with buttons and .
Easy login can be activated from top menu.

Only users with a level equal to the maximum allowed level (3 on
Visual Faris) can operate this activation or deactivation; other users
will see this function disabled .

Levels accessibility table
Level Label Attribute Accessable functions
3 LEVEL3 Supervisor Delete sample

Delete working program
Load acquired image to sample buffer
Working directories settings
Reset production report
Add new user
Enable actions traceability
Erase users actions list
Acceptability standards definition
Enable easy logon
2 LEVEL2 Programmer Terminate VisualFaris session
1 LEVEL1 Logon procedure

All programming functions
0 LEVELGENERICUSER Operator Generic user cannot logon.

Counters settings
Display acquired image with left mouse button
Display processed image with right mouse
button.
LEVELx has access to all function accessible from LEVEL0 to LEVELx.

Inspection timings
Press this button from the main toolbar to get information about time taken by various
inspection operations.
The timings window provides data about the followings :

• Acquisition: time taken for image grabbing operations on
last image.
• Processing: time taken for image analysis operations on last
image.
• Load/Unload: time taken to offload the part just inspected
and has the first position of next part ready for x-ray
acquisition.
• Cycle time: time taken to complete the inspection of last
part, including load/offload.
This window is updated in real time at every image.

Troubleshooting
Remote support for Visual Faris programming on a particular working program requires Bosello to
be provided with all samples the make part of the working program and some images of that
particular working program taken from x-ray inspection of numerous parts (wheels, castings, etc.).
X-ray inspection images collection

The working program has
to be tested by Bosello
over numerous images
taken from real production.
Visual Faris can be
configured to automatically
collect images from the X-
ray inspection cycles and
store them into a user
definable folder.
This group box allows a

user to set the images
collection and to define
the destination folder
for the collected
images.
Once the “Enable save inspection images” check box has been checked, you can restart production.
Visual Faris then starts collecting all images from the castings the X-ray unit will be fed with.
You should run the X-ray unit with the castings you’re experiencing problems with.
Once a significant lot of castings has been passed through the X-ray unit (usually 20-50), you can
disable the image collection by un-checking the proper check box.
The collected images should be transferred into a CD and sent to Bosello via express mail.
Usually the images take substantial amount of bytes and e-mail transfer will be difficult, unless you
could compress them into a zip file. Visual Faris does not provide functions to compress the
collected images, you should compress the images using common compression programs available
on the market.

Online procedures for images collection and working programs

backup/restore
Press this button from the

production window toolbar.
The following dialog box shows up.
The available
storage units appear
in the list box .
Use this
button to
refresh the list.
Removable
devices can
be safely
removed using this
button.
Images collection.
This group of functions allow to save an user defined number of images taken from castings during
normal production.
Working programs backup / restore.

These two functions do the same operations described in chapter “Management of working
programs”.

Options
Offline station
Two working set-ups are possible with Visual Faris: online and offline. Offline unit is not used for
on-line inspection; it can be used for off-line X-ray image programming.
The offline Visual Faris can be useful if the programming of new product and is designed to be
independent from the inspection of the production cycle. In this case the online Visual Faris will
deliver new images that can be programmed with the offline Visual Faris without interrupting the
production cycle.
Multi energy.
A direct link can be established between Visual Faris and Bosello X-ray generator. To allow
specific energy controls during image acquisition, refer to the proper previously mentioned chapter.
Regions of rejection coding (RejectionCodingAreas)

Specific rejection codes and messages can be associated with user-definable sample areas labelled
as RCA.
Whenever a non-acceptable defect shows up in a particular sample area , the rejection code and
message associated with the area where defect lies can be eventually notified to the production line.

Glossary
FARIS Fully Automatic Radioscopic Inspection System

SAMPLE Block of data (images and parameters) utilized by FARIS to inspect a
particular inspection view of a part
WORKING PROGRAM Collection of SAMPLES for the inspection of a part
VIEW The X-ray image of a part taken from a particular angle
SMP buffer Image of the sample
ACQ buffer Last image acquired from the imaging device
PRE buffer Image resulting from the application of the pre-processing functions on
the ACQ buffer
PROC buffer Image resulting from the application of the processing functions on the
PRE buffer
BIN buffer Image resulting from the application of the high and low thresholds on
the PROC buffer
RES buffer Image resulting from the classification of defects presents in the BIN
buffer
Noise Noise is a common term to describe all those phenomena that reduce the
image quality and is visually identifiable with the image graininess.
There are several types of noise that add their effects during the image
recording process. Light is imaged by lenses or directly onto a digital
image sensor. Once there, it interacts with the semiconductor and
generates charge carriers (electrons) that are transported out of the image
sensor. The electrons are converted into voltages and into digital
numbers by an analog to digital process. During all these processes ,
many factors reduce the signal quality and, in turn, the image quality.
ACQ Acquisition Controls

ROI Regions Of Interest
MRT Roto.Translational matching
MH Horizontal matching
MV Vertical matching
MR Rotational matching for wheels
RD Remove Datails
ROP Regions Of Processing
ROM Regions Of Magnification
LUT Look Up Table
ROB Regions Of Belonging
AWR Automatic Wheel Registration
AWI Automatic Wheel Identification

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Via Confalonieri 19

21013 Gallarate (VA)

Tel ++39 0331 776109

Title : VISUAL FARIS User Manual

Author : Moreno Savio

Rights : reserved to Bosello High Technology srl

© 2012 Bosello High Technology

Edition : February 2012

Bosello High Technology All rights reserved 2

Bosello High Technology All rights reserved 3

Wheel rim : equalize ............................................................................................................................................................... 48

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ACTUAL SAMPLE ........................................................................................................................................................... 95

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X-ray exposure of Analysis of

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Further minimum characteristics of the PC are:

We reserve the rights to change or improve without prior notice.

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Interface with X-ray unit

Visual Faris station.

• Part transportation in and out the X-ray cabinet

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This example shows a wheel with three areas to be

View Sample Valid for 8

View Sample Valid for 4

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There are three main memory locations for sample management :

• $("( (. This is the area where Samples can be programmed.

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Sample programming takes place in this area.

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Use this button to

Use this button to

Sample identification data:

Name This field represents the Sample name.

There are two options:

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This is the area where sample are stored

The upper section of this window shows a list

Right click on one of the Samples name on

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This function transfers one or more Samples from *,"(( into

This function deletes the selected Sample(s). This will permanently

This function transfers one or more Samples from *,"(( to

This function generates a zip file of the selected Samples.

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This is the area where samples can be stored

The upper section of this window shows a list

Right click on one of the Samples name on the

This functions transfers one or more Samples from  .$( to

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Default folder for generic images

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Sample images and data are displayed into a dedicated window.

Sample name is displayed into window title.

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Restore the Sample image

Copy the acquired image to the Sample buffer

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Loading an image to the acquisition buffer

• $("( (. This is the area where Samples can be programmed.

This function transfers one or more Samples from *,"(( into

This function transfers one or more Samples from *,"(( to

This functions transfers one or more Samples from .$( to