This paper introduces a new wireless solution that permits performing accurate and traceable ultrasonic scans of components with complex geometries using a hand-held scanner. The system integrates an array of 3D cameras that track the position of the hand of the inspector with a high-performance PAUT instrument to provide accurate, highresolution C-Scans on any component. This paper provides results of hand-held scans on complex composite parts,
and explores how the solution compares with traditional semi-automatic and automatic systems in terms of setup, ease-of-use, performance, productivity, and cost.
PerkinElmer Spotlight™ FT-IR Microscopy Systems are built to the highest ISO-9001 manufacturing standards. This document presents technical information and typical performance specifications based on factory tests.
The Spotlight systems take the proven and popular IR microscopy technique and add a new level of performance, automation and add applications capability. Spotlight 150i and 200i systems can be configured from a range of FT-IR, detector and microscope stage options to best suit the application requirement.
The Spotlight150i and 200i systems can be configured with either Spectrum Two or Frontier FT-IR instruments; in addition
Spectrum 100, 400 and Spectrum One FT-IR systems are upgradeable to Spotlight 150i/200i systems.
PerkinElmer Spotlight™ FT-IR Microscopy Systems are built to the highest ISO-9001 manufacturing standards. This document presents technical information and typical performance specifications based on factory tests.
The Spotlight systems take the proven and popular IR microscopy technique and add a new level of performance, automation and add applications capability. Spotlight 150i and 200i systems can be configured from a range of FT-IR, detector and microscope stage options to best suit the application requirement.
The Spotlight150i and 200i systems can be configured with either Spectrum Two or Frontier FT-IR instruments; in addition
Spectrum 100, 400 and Spectrum One FT-IR systems are upgradeable to Spotlight 150i/200i systems.
3d printer electronics engineering live projects abstracts @1000KV Technologi...1000kv technologies
electronics engineering live projects abstracts
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CHY-CB is based on contacting method and provides accurate and precise thickness measurement for plastic films, sheets, paper, foils, silicon wafers and sheetings. Test results will display in real time along with max, min and average value.
THRIS (Telecom Hardware Robustness Inspection System) is an automatic qualification and test environment developed in co-operation by CSELT, the central research laboratory of the STET group in the telecommunication field, HP and HDT under commitment of Telecom Italia.
THRIS is a new conception tool focused on the most critical issues affecting the quality of telecom hardware, well suited for both operating companies and manufactures. It can be utilised with great benefits and cost savings through the entire life of a telecom product from the early design stage up to field operation.
Phased Array Pipeline Zone Discrimination InspectionOlympus IMS
PipeWIZARD details: http://bit.ly/1woKWdN
The Girth Welds used to connect pipe across country or offshore for the transportation of petroleum must be inspected during construction to ensure safe operation. In order to prevent inspection from bottlenecking the construction process, the inspection method must be rapid, repeatable and meet applicable code requirements.
By using fully automatic zone discrimination systems deployed on and offshore, Phased Array ultrasound is increasingly used to meet this need. In this application note, read about the advantages of Phased Array versus Radiography, and the benefits of inspections with the PipeWIZARD.
Contact us: http://bit.ly/1rDmq94
Sign up for our Newsletter: http://bit.ly/1j5FOTy
3d printer electronics engineering live projects abstracts @1000KV Technologi...1000kv technologies
electronics engineering live projects abstracts
electronics projects, electronics projects for engineering final year students, electronics and communication engineering projects for final year students,100kv,1000kv,1000kv technologies,1000kv projects,technologies,live projects,Hyderabad live projects,live projects in, diploma low cost projects,1000kv projects, , academic projects,btech live projects,Hyderabad,1000kilovolts,1000kilovolts technologies ,btech main projects ,
CHY-CB is based on contacting method and provides accurate and precise thickness measurement for plastic films, sheets, paper, foils, silicon wafers and sheetings. Test results will display in real time along with max, min and average value.
THRIS (Telecom Hardware Robustness Inspection System) is an automatic qualification and test environment developed in co-operation by CSELT, the central research laboratory of the STET group in the telecommunication field, HP and HDT under commitment of Telecom Italia.
THRIS is a new conception tool focused on the most critical issues affecting the quality of telecom hardware, well suited for both operating companies and manufactures. It can be utilised with great benefits and cost savings through the entire life of a telecom product from the early design stage up to field operation.
Phased Array Pipeline Zone Discrimination InspectionOlympus IMS
PipeWIZARD details: http://bit.ly/1woKWdN
The Girth Welds used to connect pipe across country or offshore for the transportation of petroleum must be inspected during construction to ensure safe operation. In order to prevent inspection from bottlenecking the construction process, the inspection method must be rapid, repeatable and meet applicable code requirements.
By using fully automatic zone discrimination systems deployed on and offshore, Phased Array ultrasound is increasingly used to meet this need. In this application note, read about the advantages of Phased Array versus Radiography, and the benefits of inspections with the PipeWIZARD.
Contact us: http://bit.ly/1rDmq94
Sign up for our Newsletter: http://bit.ly/1j5FOTy
PC-based Vision System for Operating Parameter Identification on a CNC MachineIDES Editor
Identification of suitable or optimum operating
parameters on a CNC machine is a non-trivial task. Especially
when the material of the component changes, operating
parameters need to be suitably varied. In this paper, a PCbased
vision system is presented for the automatic identification
of component material and appropriate selection of operating
parameters. The objective of this work is to develop a support
system to aid the operator in quick identification of machining
parameters
Testability refers to the design parameter which makes it relatively easy to identify and isolate faults in the system. Testability can be considered to be a subset of maintainability, because fault detection and isolation are important drivers in the maintainability of a system
BIST (Built-in-Self-Test) Features for Electronic Valve ActuatorsMead O'Brien, Inc.
The development and implementation of safety related devices in plant systems is crucial for dependable operation, not to mention peace of mind. Safety and safe operation were once only high priorities for installations that involve hazardous environments. Expensive certification testing was, and still is, paramount to meeting the hazards of such environments, but a new level of plant-wide integrity is emerging — that of Safety Integrity Level (SIL) and SIS. SIL is a safety rating that can be derived by analyzing a system to determine the risk of a failure occurring and the severity of its consequences. Safety Instrumented Systems (SIS) are systems containing instrumentation or controls installed for the purpose of preventing or mitigating a failure either by emergency shut down (ESD) or diverting the hazard. New or replacement equipment must have the ability to be introduced into plant systems without jeopardizing either the SIL of the operation or negatively impacting the SIS.
Disturbance Observer And Optimal Fuzzy Controllers Used In Controlling Force ...theijes
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
A Novel Idea on Semi-Automated Operation Theatre Assistance for Doctors Based...theijes
The idea of this article is to develop a robotic assistant for handling surgical instruments in Operation Theatres. Hence it is possible to minimize human intervention in turn the risk of contamination and the probability of human error. The robotic system principally has three functional parts : locomotion controlled by Bluetooth from an android device; rotatory array of medical instruments governed by a stepper motor that functions over a voice input and a robotic arm made of Gripper motor controlled remotely.
Enhancement in NDT inspection for operational effectiveness, efficiency and e...Innerspec Technologies
We intend to show that any change shall be linked, not only to improvement, but also to immediate cost reduction so that all management structure can conceive quick implementation as
part of its department strategy & enhancement in their budget cost.
For that, concepts such as effectiveness, efficiency and excellence must be approached. We will give clear saving cost ways which will follow the terminology.
In Financial terms and without a deep analysis, we can conrm cost savings above 30% from current prices are achieved.
In last meeting in Davos (Switzerland) in January, the World Economic Forum, expressed its decision to expand investments in green energy. Many new projects are going to be present in the next years.
It is expected a erce competition among companies to be awarded with contracts that will secure their businesses. Some companies have been leading the renewable market for years and they have built a substantial moat which place them in an invaluable position in the market. However, though a good start point, it is not unwavering.
It is time for them to start looking forward and push everyone around to join the industry trend 4.0 also enforced by the Forum. Moving in the right direction will end the controversy of Quality Vs. Production which has dragged down many projects damaging company's image.
Application of conventional NDT methods to supervise the quality has been burdening progress. Production department has been reticent to implement advanced NDT techniques based on wrong concepts.
It is time for NDT companies to look at the industry in the right way, showing that there is a way to work for all. Just by moving forward.
In the next lines, we will try to show and explain that NDT industry must lead the progress introducing FEA analysis in their reports if they want to join all stakeholders around project success.
In the fall of 2002, Innerspec introduced and patented an Ultrasonic Testing (UT) inspection system for surface inspection of mill rolls. This novel approach was designed to overcome known limitations of Eddy Current (EC) systems.
In 2014, Whemco Steel Castings Inc., a leader in mill roll manufacturing and service, approached Innerspec Technologies to expand the original Rollmate design with more capabilities.
When challenged to develop a new generation of mill roll inspection systems, Innerspec embraced the task and sought to design a comprehensive solution using the best NDT techniques available for the task.
The system is fully designed and manufactured in the United States, and serviced and supported by Innerspec offices in the US, Mexico, Europe and China.
The objective of this paper is to study how the selection of the coil and the frequency affects the received modes in
guided Lamb waves, with the objective of analyzing the best configuration for determining the depth of a given
defect in a metallic pipe with the minimum error. Studies of the size of the damages with all the extracted
parameters are then used to propose estimators of the residual thickness, considering amplitude and phase
information in one or several modes. Results demonstrate the suitability of the proposal, improving the estimation of
the residual thickness when two simultaneous modes are used, as well as the range of possibilities that the coil and
frequency selection offers.
Sistema de inspección híbrido EMAT-Visión para optimar el proceso de fabricac...Innerspec Technologies
Uno de los principales retos a los que se enfrenta la industria del automóvil es la reducción del peso de partes estructurales, sin que esto afecte a la seguridad del producto final. La fabricación de Tailor Welded Blanks (TWB) en la industria del automóvil es un proceso avanzado que consiste en combinar varias chapas finas de metal que son soldadas mediante tecnología láser antes del proceso de estampado. Aunque la inspección de TWB suele llevarse a cabo mediante la tecnología EMAT, ésta presenta ciertas limitaciones a la hora de identificar defectos superficiales tales como el desalineamiento lateral y vertical de una chapa respecto a otra. Con el fin de
afrontar esta limitación, los fabricantes inspeccionan las chapas con un equipo adicional de visión artificial que complementa los resultados del equipo EMAT. Este artículo presenta el nuevo sistema de inspección OPTIBLANKS, que es el primer equipo híbrido que combina EMAT y visión artificial para establecer un criterio de aceptación/rechazo unificado a través de la combinación de la información proporcionada por ambas tecnologías no destructivas. Esta hibridación dota al sistema final de más inteligencia, lo que le permite tomar decisiones más robustas y optimizar el proceso de fabricación y la calidad del producto final. El artículo presenta los resultados del proceso de validación de OPTIBLANKS en una planta de fabricación de TWB (Gestamp Solblank). Los resultados muestran la necesidad de combinar la información de las dos técnicas para incrementar la probabilidad de detección (POD) del sistema de inspección.
Detección de delaminaciones y otros defectos de unión en productos de acero m...Innerspec Technologies
Ondas guiadas superficiales (Rayleigh) y tipo Lamb fueron usadas para la detección de delaminaciones, residuos de acero embebidos en la matriz del material y problemas de adherencia de la frágil capa intermetálica de Al-Fe en la interfaz formada por el aluminio revestido y el acero generados durante el
proceso de laminación en frío “Cold Roll Bonding” (CRB). Se fabricaron muestras multicapa con defectos artificiales de distintos tamaños, localizados entre el aluminio recubierto y el acero. El objetivo de este manuscrito es mostrar la sensibilidad de las ondas guiadas EMAT para indicar cualitativamente
la presencia de defectos, utilizando para ello técnicas de atenuación de la señal adquirida. Para la generación y recepción de las ondas guiadas se usaron transductores acústico-electromagnéticos (EMAT) dispuestos en configuración pitch-catch (transmisión-recepción). La toma de medidas se llevó a cabo en el material laminado antes y después de aplicar el recocido, de forma que se pudieran evaluar las diferencias que el tratamiento térmico provocaba en términos de atenuación y de relación señal-ruido (SNR). El modo S0 de onda Lamb se demostró adecuado para la detección de delaminaciones y residuos de acero embebidos en la matriz
del material, existiendo una relación entre el grado
de atenuación y, el tipo y tamaño de defecto, así
como con la realización del recocido. Sin embargo
dicho modo no pudo detectar falta de adherencia
de la frágil capa intermetálica de Al-Fe debido a los
espesores de la capa de aluminio recubierto y del
acero. Secciones de las muestras inspeccionadas
con EMAT fueron posteriormente evaluadas metalográficamente para corroborar las indicaciones de
defecto. Los resultados demostraron la viabilidad del uso de ondas guiadas Rayleigh y Lamb para la detección de defectos de unión en la producción en serie de planchas bimetálicas de Al-Sn/Acero.
Nondestructive Testing (NDT) has evolved from being a “necessary evil” to being an essential source of competitive advantage. The right technique not only helps control the quality of the final product, but also provides valuable process control feedback to improve productivity, reduce cost, and increase the
efficiency of the welder. This is especially important in high-volume, continuous processing lines where a few minutes of bad production can result in significant losses.
In the last decade, powerful Ultrasonic EMAT technology has come of age with tremendous success, becoming the technique of choice for many applications.
Final strip and sheet steel product is commonly inspected with great scrutiny to qualify material for high-end product requirements. Surface flaws such as slivers, cracks, laps, etc., disqualify these materials from being used in automotive and big box applications. Internal defects such as voids, cracks, laminations, porosity and segregation may remain undetectable with surface inspection methods as they have not yet manifested at the surface. These internal defects often propagate to the surface where ultimately they are detectable in the finished product stage in the form of slivers, blisters, etc., although remaining undetectable in the steel making, hot-rolling, pickling, cold rolling and subsequent finishing operations. Surface flaws are a key cause of down grading of finished product and a significant cost to the steel maker as all value added operations are complete before detection and down grading are possible.
In today’s competitive environment, it is key to maximize utilization of mill assets and to avoid adding value to material which can be known early in the manufacturing process to contain deleterious defects. Using proven methods of volumetric material inspection in two separate case studies, methods have been developed to allow the steel maker to identify poor material early in the process thus avoiding the value added processes on these materials and only processing materials which with a probability of final inspection passage.
The United States consumes an incredible amount of energy every day, and this demand for energy shows no signs of decreasing. The U.S. pipeline infrastructure is critical to supporting this growing demand. We take a look at this infrastructure and break down some of the facts including age, material, miles and production.
To learn more about energy production in the U.S. visit the U.S. Energy Information Administration or contact one of our oil & gas sales engineers.
The field of Non Destructive Testing (NDT) has shown tremendous growth in the last half century. Its ability to provide safe volumetric inspection of materials with limited access areas makes ultrasonic testing (UT) one of the fastest growing technique in NDT.
However, the Achilles heel of Ultrasonic Testing (UT) has always been the transferring of energy from the UT probe into the material subject of the inspection. Because air limits the transfer of ultrasound, the transducers need to be coupled to the material using a liquid that promotes the transfer of energy into the material.
Austenitic welds are extensively used in nuclear, petrochemical and process industries. Due to the strong material anisotropy and coarse grain size in the dendritic weld zone, they are difficult to inspect with ultrasound. In this regard, the shear horizontal (SH) wave mode is far superior to the more conventional shear vertical (SV) and longitudinal wave modes. In this paper, an electromagnetic acoustic transducer (EMAT) is designed and used for the inspection of two austenitic weld samples. Despite the low efficiency of EMAT generation due to low conductivity of austenitic stainless steel material and strong attenuation in the weld zone, good signal to noise ratio is achieved with optimized EMAT probes and state-of-the-art instrumentation. The angle beam EMAT probe successfully detected all defects in the samples with good signal to noise ratio including a 2% defect.
The capability of detection a defect across a 2’’ inch thick and 2’’ wide austenitic weld zone is also demonstrated in the paper.
Electric Resistance Weld (ERW) tubes and pipes are extensively used un many applications including Oil Country Tubular Goods (OCTG) and high quality structures. Efficient in-line nondestructive testing techniques are needed to ensure that the weld quality meets applications standards.
In the fall of 2002, a revolutionary method by which to inspect mill rolls was introduced to the metal producing industry. This ultrasonic approach was designed to overcome the inadequacies of existing inspection techniques while
maximising return on investment. Since then, a number of improvements have been made, and with input from many
roll shops, the latest technologies provide the most comprehensive tool available for the inspection of all types of mill rolls. This paper provides an overview of mill roll
inspection technology and the effects that various inspection technologies can have on the efficiency and costs associated with operating a roll shop. It will also highlight how new techniques provide alternatives otherwise not available.
Clad metals are composite metal containing two or more layers that have been bonded together. The bonding may have been accomplished by rolling, extrusion, welding, diffusion bonding, casting, heavy chemical deposition, or heavy electroplating. Clad metals offer the opportunity to combine desirable properties and/or characteristics of individual metals and alloys into a material "system" that provides improved characteristics over the individual metals. In the event the bond quality is compromised, these materials will not meet their original purpose. Disbond in clad layers is very similar to an internal void in single layer materials such as steel strip material.
Clad metals are multilayered metals containing two or more layers that have been bonded together. This bonding can be accomplished by cold or hot rolling, extrusion, welding, diffusion bonding, casting, heavy chemical deposition, or heavy electroplating.
This paper introduces a new application of guided wave electromagnetic acoustic transducers (EMATs) for the detection of delamination in a brass/copper/brass three-layered composite used for coin stock. In addition to detection, using finite element analysis and guided wave modal analysis, it was possible to model and explain the results for different discontinuity sizes and geometries.
Ultrasonic guided wave techniques have great potential for structural health monitoring applications. Appropriate mode and frequency selection is the basis for achieving optimised damage monitoring performance.
In this paper, several important guided wave mode attributes are
introduced in addition to the commonly used phase velocity and group velocity dispersion curves while using the general corrosion problem as an example. We first derive a simple and generic wave excitability function based on the theory of normal mode expansion and the reciprocity theorem. A sensitivity dispersion curve is formulated based on the group velocity dispersion curve. Both excitability and sensitivity dispersion curves are verified with finite element simulations. Finally, a
goodness dispersion curve concept is introduced to evaluate the tradeoffs between multiple mode selection objectives based on the wave velocity, excitability and sensitivity.
While research and development of Electro-Magnetic Acoustic Transducer (EMAT) technology has been active for several decades, hardened production inspection system applications remain limited. Applications remain limited despite the several and distinct advantages and EMAT probe can have over conventional piezoelectric ultrasonic devices.
In addition to being comparable in ultrasonic wave mode generation and sensitivity, under proper design, an EMAT probe offers the following advantages for the production minded engineer: (1) no fluid couplant is required, (2) the test can be non-contact, (3) works on rough, dirty, and hot surfaces, (4) can be operated at very high scan rates, (5) easy to automate, and (6) capable of generating useful waves modes that are difficult to generate with piezoelectric devices. Basic elements of an EMAT system are explained and a comparison to conventional piezoelectric devices is made. By using real application cases, the benefits of EMATs are demonstrated. These real cases include: (1) flash butt-weld inspection, (2) mill roll inspection, (3) automotive laser weld inspection, and (4) tube & pipe inspection.
Austenitic welds are widely used in nuclear, petrochemical and process industries. The strong material anisotropy and coarse grain structure in the dendritic weld zone makes these welds very difficult to inspect with conventional techniques. It is well-known that the shear horizontal (SH) wave is well-suited for this inspection and that electromagnetic acoustic transducer (EMAT) is the best technique for generating this wave mode, but the lack of equipment has precluded its application in the field. This paper presents the development of one channel and phased array EMAT systems and results from tests conducted on samples provided by the Electric Power Research Institute (EPRI). The results show the potential of this new equipment
for austenitic weld inspection, which opens up new possibilities for research and field use.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
Sachpazis:Terzaghi Bearing Capacity Estimation in simple terms with Calculati...Dr.Costas Sachpazis
Terzaghi's soil bearing capacity theory, developed by Karl Terzaghi, is a fundamental principle in geotechnical engineering used to determine the bearing capacity of shallow foundations. This theory provides a method to calculate the ultimate bearing capacity of soil, which is the maximum load per unit area that the soil can support without undergoing shear failure. The Calculation HTML Code included.
Final project report on grocery store management system..pdfKamal Acharya
In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services.
Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options.
In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
This document will discuss each of the underlying technologies to create and implement an e- commerce website.
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Explore the innovative world of trenchless pipe repair with our comprehensive guide, "The Benefits and Techniques of Trenchless Pipe Repair." This document delves into the modern methods of repairing underground pipes without the need for extensive excavation, highlighting the numerous advantages and the latest techniques used in the industry.
Learn about the cost savings, reduced environmental impact, and minimal disruption associated with trenchless technology. Discover detailed explanations of popular techniques such as pipe bursting, cured-in-place pipe (CIPP) lining, and directional drilling. Understand how these methods can be applied to various types of infrastructure, from residential plumbing to large-scale municipal systems.
Ideal for homeowners, contractors, engineers, and anyone interested in modern plumbing solutions, this guide provides valuable insights into why trenchless pipe repair is becoming the preferred choice for pipe rehabilitation. Stay informed about the latest advancements and best practices in the field.
The Benefits and Techniques of Trenchless Pipe Repair.pdf
Camera Encoded Phased Array for Semi-Automated Inspection of Complex Composite Components
1. Camera Encoded Phased Array for Semi-Automated Inspection of Complex
Composite Components
Borja Lopez
Innerspec Technologies, Inc.
2940 Perrowville Road, Forest, VA 24551, USA
blopez@innerspec.com
Source: Nondestructive Evaluation of Aerospace Materials & Structures 2018 (ASNT)
ABSTRACT
This paper introduces a new wireless solution that permits performing accurate and traceable ultrasonic scans of
components with complex geometries using a hand-held scanner. The system integrates an array of 3D cameras that
track the position of the hand of the inspector with a high-performance PAUT instrument to provide accurate, high-
resolution C-Scans on any component. This paper provides results of hand-held scans on complex composite parts,
and explores how the solution compares with traditional semi-automatic and automatic systems in terms of setup,
ease-of-use, performance, productivity, and cost.
Keywords: wireless encoding, 3D camera encoding, Phased Array of composites, semi-automated inspection.
INTRODUCTION
A basic premise in project management is called the Triple Constraint or Iron Triangle of Time-Quality-Cost.
Experienced project managers like to remind their supervisors or clients that they can choose fast, good, or cheap,
but only two at a time.
A common solution to push the boundaries of this triad is by increasing the level of automation in a process. A
higher degree of automation is typically associated with more output, better quality, and, despite the initial higher
cost, a cheaper alternative for large-volume production. For NDT in manufacturing, this has meant the introduction
of in-line and off-line integrated inspection systems with increasing degrees of sophistication. These systems can be
run by line operators without NDT expertise, and still deliver permanent records of inspection to demonstrate
compliance to a customer or regulator. In these manufacturing environments, manual inspections are increasingly
relegated to MRO (Maintenance, Repair, Overhaul) processes that are characterized by low volumes and complex or
difficult to access components. The findings and quality of records on a manual inspection will be ultimately
dependent on the quality, training, and experience of the NDT practitioner.
In these manufacturing environments, the challenge arises when quality inspections and a permanent record is
demanded, but the complexity of the component or limited production volumes do not justify the investment in an
automated inspection system. This problem is compounded when there is limited access to qualified and
experienced NDT inspectors to perform the work and certify the results.
The solution many times involves semi-automated scanners, crawlers or similar devices that are mounted on the part
for complete or partial scanning. These systems are typically limited to simple-geometry parts since they do not
have the mechanical flexibility of robots, and the ability to provide accurate 3D encoding to match the inspection
results with the actual geometry of the component. Also, setup, inspection, and interpretation still require trained
NDT personnel.
This paper introduces an innovative solution to perform advanced ultrasonic inspections on complex parts with very
limited setup costs and investment. The system integrates an advanced phased array ultrasonic system (PAUT) with
2. an array of infrared (IR) vision cameras to provide three-dimensional (3D) spatial location of the probe on manual
inspections. The system provides a complete C-Scan of the part with sub-millimeter positioning accuracy on very
large parts, completely eliminates the need for mechanical encoders, and can be used on parts of any shape.
This encoding technique can also be used to simplify an upgrade from conventional UT to advanced PAUT on an
existing inspection cell by eliminating the need to integrate the ultrasonic instrument with the line robot or gantry.
The results presented are from actual systems used for inspection of Carbon Fiber Reinforced Polymer (CFRP) used
in aerospace. The same technique can be used for inspection of forgings, or other large components of any shape.
The system and technique was originally developed by Tecnatom S.A. in Madrid (Spain), and has been adapted for
the North American market by Innerspec Technologies Inc. in Forest VA (USA). It is currently commercialized
under the WiiPA name in Europe, and CAMUS 3D in North America.
DESCRIPTION OF EQUIPMENT
Figure 1 shows a block diagram of the main components of the inspection system.
Figure 1. Block diagram of the UT inspection system based on infra-red visual tracking.
The system includes:
Data Acquisition System (DAS). The PAUT instrument is based on Tecnatom’s SONIA platform and
InspectView software.
UT Assembly. Includes a 32 or 64 element linear Phased-Array probe, custom wedges for mechanical contact
to the part surface, a bubbler for ultrasonic coupling in local immersion, a device for ergonomic handling of
the assembly, and the IR markers for spatial location of the complete assembly (small spheres reflecting light
in the infrared spectrum).
3. Infrared Vision System. This system contains several infrared cameras (from 3 to 20), depending on the
size of the part inspected. These cameras are placed in the cell so at least three cameras have always a direct
line of vision to the UT Assembly. The special triangulation algorithms processed in real-time by a central
processing unit (CPU) generate the 3D positioning coordinates of the UT Assembly, which are transferred to
the DAS to generate the C-Scan of the part.
Water Management. The bubbler holding the transducer is continuously supplied by a small water flow for
proper ultrasonic coupling. A tray collects the overflow which is filtered and pumped back to the UT
Assembly.
Part Fixture. Holds the part and provides mechanical stability during the inspection process. The Part Fixture
also includes IR markers for correct mapping of the UT Assembly on the part.
The inspection technique is a linear Phased-Array UT Pulse-Echo (PAUT-PE) with custom transducer and wedges to
adapt to any of the geometries that are found in production parts (inner/outer radius, ramp, basins, etc.). The sensors
can run at different frequencies (typically 3.5 or 5 MHz) to meet the inspection needs.
Figure 2 shows an example of a standard implementation of the solution in an industrial environment. In this
configuration, the system has eight IR cameras installed at the top of a metallic structure to ensure that the UT
Assembly is followed by at least three cameras at all times. The structure also permits wiring and piping for the UT
Assembly and holds the DAS and screens used by the inspectors to monitor the results.
Figure 2. Industrial implementation of a inspection cell based on IR visual tracking.
INTEGRATION CHALLENGES AND SOLUTIONS
UT inspection and IR 3D scanning are known technologies that are frequently used independently. This section
covers the integration challenges and the custom solutions developed for this innovative application.
Ultrasonic Coupling. There are several coupling methods to perform PAUT-PE inspections, in manual or
semi-automated inspections. A probe bubbler with custom wedges was the method selected because of its
reliability and productivity. Use of dry-coupling techniques is currently being investigated but has not yet
been implemented due to severe limitations for inspection of curved shapes.
Ergonomics. Considering that the inspection is performed manually, the ergonomics of the Part Fixture and
UT Assembly are critical to provide a safe and productive work environment. Each part needs to be properly
analyzed prior to installation to set up the right height of the fixture and monitors, and permit comfortable
scanning of all surfaces.
4. Figure 3. Detail of ergonomic implementation of the IR markers on the UT module.
Human-machine Interaction. Together with ergonomics, proper design of the human-machine interface is
critical for safety, reliability, and productivity. The CAMUS 3D interface has been optimized to provide real-
time and easy-to-interpret C-Scans with an accurate depiction of the location of the probe. The system
includes controls so the operator can easily pause and resume the inspection without losing data, and re-scan
and overwrite areas of the part without compromising the integrity of the results. The equipment also permits
merging the information from several operators working on the same part, or even having several inspections
on different parts in the same inspection cell.
Latency Control. One of the key integration components with IR tracking systems is the time required by
the IR system to process the spatial coordinates and transfer the information to the UT instrument, which can
take tens of milliseconds. Even though manual inspection speeds are typically low (less than 150 mm/sec)
this latency can cause hysteresis phenomena that will distort the C-Scan results. To avoid this problem,
especially when the IR tracking system is mounted on faster robotic lines, the technique requires software
controls designed specifically for integration between the IR and UT systems.
Resolution, Accuracy, and Repeatability. UT inspection of parts with complex geometries typically
requires resolution, accuracy, and repeatability between 0.1mm and 1mm. These requirements involve good
mechanical characterizations of the component, the Part Fixture, the UT Assembly as well as fast and
accurate calibrations of the IR cameras with three-point correction tools. Fast calibration is also important to
quickly resume work if there is an undesired movement on the part, cameras, or Part Fixture.
Lighting. IR tracking systems can be affected by direct or reflected infrared light from natural or artificial
sources causing location errors. To avoid these errors, IR markers need to be set in a pattern that is easily
tracked by the vision system. This is also important during the design of the inspection cell so the cameras
are not affected by light sources or reflections from outdoor windows, mirrors, lamps, etc.
3D Analysis and Rendering. Since CAMUS 3D is primarily used to scan complex geometries, it is
paramount that the results are also analyzed and provide interpretation in easy-to-interpret 3D renderings.
InspectView software provides tools to incorporate CAD data and overlay the inspection results on the
imported file. In addition to this, all UT results are analyzed based on the actual volumetric configuration of
the part for proper sizing and interpretation of the results. The inspection data can be presented in 3D and 2D
formats for analysis by the inspectors based on different code requirements and personal preferences. Figure
4 shows one of the available tools for 3D rendering and analysis.
5. Figure 4. Software tool to adapt complex geometries for 3D inspection environment.
Combined Part Records. InspectView software for CAMUS 3D is designed so all the files from inspections
of one part can be merged into one single Part Record. This is especially relevant when the part has been
inspected at different times using probes and wedges adapted to the geometry of different sections. A typical
example is found in the inspection of parts combining flat surfaces and radii (either inner or outer) that are
common in aerospace. In these cases, having different scans combined into one Part Record facilitates final
analysis and record keeping.
RESULTS
Figures 5 and 6 show some examples of C-Scan records produced with a CAMUS 3D system. Data from CFRP
reference blocks with artificial defects are shown. Images show two magnitudes: signal amplitude and sound path.
Both images are of high quality and homogeneity.
Figure 5. Comparative view of C-Scan records, both in amplitude and sound path. Obtained with the
CAMUS 3D inspection system on a CFRP reference block (pulse-echo technique, 5 MHz)
6. Figure 6. Comparative view of C-Scan records with amplitude signal. Left: data acquired with automated
inspection system (water tank). Right: data acquired with semi-automated inspection system (Pulse-echo
technique, 3.5 MHz)
Depending on the flexibility of the part, the rigidity of the holding fixture, and the UT technique, amplitude records
may reveal slight variations due to the changes in pressure applied by the inspector. These changes are usually
below 1dB, well within the tolerances for aerospace standards.
It is important to note that all the defects have near perfect resolution and there is no hysteresis observed even at
speeds of 500 mm/s.
FASTER, BETTER, CHEAPER
Manual and semi-automated inspection systems are usually associated with low productivity when compared to
automated solutions and typically relegated to the inspection of small parts. One of the main advantages of
combining visual tracking with manual PAUT techniques is the ability to inspect very large parts with complete
reliability and at fast inspection speeds. A CAMUS 3D inspection cell can accommodate parts that are up to 30m
long, and have several inspectors scanning the part at the same time.
The inspection process is similar to painting with a broad brush. The monitor provides immediate feedback of the
location of the brush and the results of the “painting” on the part. The real-time scan delivers instantaneous
information on the quality of the results, and whether an area has been properly covered. This feedback permits
operators to retrace their steps, increase or reduce the speed, or change angle and pressure depending on shape and
geometry, surface conditions, and other inspection variables. The CAMUS 3D system has been measured to provide
an average inspection speed on flat areas of approx. 200 mm/s, with productivity of 20 m2
/h. These values are
typically in between those achieved with conventional semi-automated and fully automated solutions.
Another very important factor contributing to the high productivity of this equipment is new-part setup and part-
change times. By eliminating robot programming, new parts can be configured in a matter of hours, while parts can
be moved in and out of the fixture and be ready to inspect in minutes. Also, based on practical experience, CAMUS
3D has a clear advantage over fully automated systems when inspecting large and less-rigid parts where slight
variations in shape during manufacturing, or flexing of the part when on the fixture can cause position variations that
robots cannot handle, but a human inspector can easily accommodate.
From a cost point of view, a full CAMUS 3D inspection cell will typically cost 60-80% less than an equivalent
robotic line and it requires considerably less space, maintenance, and safety considerations. This equipment can be
7. delivered in 2-3 months and installed in a couple of days compared to the standard 12 months required for a fully
automated line.
CONCLUSIONS
This paper shows how IR visual tracking technology has been integrated with a high-end PAUT instrument and
software to provide wireless 3D encoding during manual inspections. Depending on the part and production
volumes, this semi-automated tool can provide equivalent or better quality and productivity than a fully automated
solution at a fraction of the cost. This encoding technique can also be used to upgrade a conventional UT inspection
cell to PAUT without having to manipulate or reprogram the inspection robots or gantries.
Future work includes adding other scanners and techniques (e.g. EMAT), and improving the man-machine
interaction using augmented reality and similar techniques.
REFERENCES & ACKNOWLEDGMENTS
This paper has been adapted for ASNT from an original version delivered at ECNDT by Mr. Fernando Ojeda
(Tecnatom). The work is supported by several national and international patents, and has been possible thanks to a
technology transfer agreement with FADA-CATEC, the effort of many people in Tecnatom and Innerspec, and to
the contribution and feedback of aerospace component manufacturers, such as Corse Composites Aéronautiques
(CCA), Turkish Aerospace Industries (TAI), Aernnova Illescas, Componentes Aeronáuticos SA (COASA), Airbus,
and Lockheed Martin.