1. Development of Industrial CT System for 2D/3D Tomographic Images of Concrete Core and Polymeric Insulators Prof. Dr. Walmor Cardoso Godoi Universidade Tecnolgica Federal do Paran UTFPR Curitiba - PR e-mail: walmorgodoi@utfpr.edu.br url: http://www.walmorgodoi.com/utfpr

2. Research Group - CNPq Instrumentao Aplicada ao Diagnstico em Materiais (Applied Instrumentation in the Diagnostic Materials) Dr. Vitoldo Swinka Filho LACTEC Dr. Sebastio Ribeiro Junior - LACTEC Dr. Klaus de Geus COPEL / UFPR Curitiba Dr. Walmor Cardoso Godoi UTFPR Dr. Guilherme Cunha da Silva LACTEC Chief of Materials Division 3. Purpose of this seminar Report of the team experience on the development of industrial CT systems: Materials and system components; mechanical and electronic instrumentation; development of acquisition and software reconstruction of CT images; calibration and tests with phantoms; R&D cases. 4. Motivation Demands of R&D to the electricity sector (generation, distribution and transmission) financed by ANEEL Analysis of Concrete Dams by 3D Computer Tomography: Tomographic images of concrete cores (withdrawals of dams) and mechanical simulation Electrical Components Analysis by Three Dimensional Tomography: Polymeric insulators used in power distribution lines (visualization of internal voids, inclusions and paths for partial discharges) Development of Portable Digital Radiography System for Insulators 5. What we need?resolution ? X-ray source kVp ?C, C++, C#, SDK 2D reconstruction 3D surfasse and volume renderinghttp://dc118.4shared.com/doc/6zREeEpt/preview.html 6. Development of new tomographic systems Main points conceptual design to attend the demand; mechanical and electronic instrumentation, which includes computer interface. X-ray source and detector Software development 7. Materials and Methods The assemblies of CT systems was performed at the Institute of Technology for Development - LACTEC, located in CuritibaPR: 90's bought the first industrial CT System. Development research: buying national components for mechanical structure; importing x-ray source, x-ray digital detector, precision rotation stage for rotating the samples. involvement master science and doctoral students. 8. CT System No. 1 First industrial CT system of Paran Gilardoni Italy fluoroscopy and radiographic applications Industrial tomography was necessary modify acquisition data set (line by line -> frame by frame)Table - sample holder 9. CT System No. 1: industrial CT system suited Gilardoni - Italy Image Intensifier Tomographic System Modification: CCD detector was replaced by 1 TV Camera (Low resolution 640x480 pixels, behind intensifier)DC Motor PILead shielding walls X-ray Source 160 kV, 10 mA, Focus 4mmx4mm Sample holder - 1 PI Precision stage samples rotation First developed software in Delphi 10. Defects in WoodQUOIRIN, 2004 MSc Dissertation http://www.pipe.ufpr.br/portal/defesas/dissertacao/059.pdf 11. Concrete core 12. Concrete coreradiographic image 13. CPU x GPU CT application for concrete samples extracted from a power plant dam as well as performance comparisons between the CPU standard ray casting algorithm and the GPU-based - ISPT-Cape Town - 2012 14. CT System No. 2: CT system for NDT in polymeric insulators build at Lactec wall with 1 mm lead 15. Detector Flat Panel Frame grabber interface - PCI board a-Si 50umx50um pixel size SDK FOV: 12x11 cm 16. Demand - R&D ANEEL ProjectvoidsPolymeric insulators 17. X-ray source Microfocus ThermoKevex Microfocus Focus: 10 um x 10 um 20 70 kVp 0 a 100 uA 18. Materials and Methods Mechanical structure Made of aluminum 1300 mm to shift the main car The rotational movement is bidirectional and unlimited. 19. Materials and Methods Mechanical structure Tomographic table Horizontal translation, and vertical translation of the sample were automated 2 stepper motors (the motor rotates 360/400 = 0.9 degrees per step)-> Low resolution 1 PI Precision stage samples rotation (from Gilardoni system) 20. Materials and Methods Mechanical structure Pulleys spindle synchronization Lifting 21. Materials and Methods Comercial Softwares and development LABVIEW - early testing, instrumentation and prototyping Matlab software prototyping MS VS (C++ and C#): Software aquisition (hardware interface), 2D and 3D image reconstruction VTK (Visualization Toolkit) : 3D volume rendering and 3D surface rendering 22. Eletronic instrumentation Function: Control the movements of the tomographic table made by USB interface, parallel port,... Command through the parallel port of the computer: electronic circuit developed using 12-optocouplers type OP4N25A. 23. Example: Optocouplers numbered 1-4 receive signals triggering the coil command auxiliary relays 24. The circuits are in a control panel 25. Manual positioning Joystick - to position the table with sample manually 26. Software: Digital radiography and tomography C++ language SDK 27. Calibration We used a standard sample (phantom) acrylic, concrete, aluminumCT phantom acrylic. (a) Using 8 pulses on the stepper motor to rotate the table and (b) using 9 pulses (or step of 0.9 degrees). 28. acrylic Phantom - 12 holes CT phantom acrylic using precision rotation stage motor to rotate the table 29. Polymeric Insulator 30. Analysis of bubbles in Insulators pulley type 31. 3D Tomography VTK Visualization Toolkit 32. Scatter diagram Neural network for automatic recognition of defects in insulators Parameters obtained from the 3D tomography 33. Mortar 34. Applications - Dentistry tooth Hamamatsu x-ray detector 35. Food(above) Pinho, an edible pine (below) Araucria (Araucaria angustiflia)Tomographic slice of a Pinho"curi'i ty(b) ba", which in Guaran language means " very Pinho " 36. Foam 37. CT System No. 4: Shielding and the current workstation at Lactecradiation-shielded cabinet 38. Actual CT System HardwareX-ray source 225 kVp, 10 mA Concrete core 39. Motorized Rotary Stage Precision Rotation Stage Continuous Rotation Range Ultra-High Resolution Max. Velocity 90 deg/sec DC-Servo, Stepper-Motor and Manual Drives Axial force 650 N SDK ( Labview and C language)http://www.physikinstrumente.com 40. Acquisition of 180 projections (.his filetype images) using a Flat Panel (16 bits, 4096 x 4096 pixels, 200 um/pixel)Tomographic reconstruction with software developed by the research team2D and 3D software developed for this CT system 41. Demand - R&D ANEEL Project d = 15 cmSAMPLES Withdrawals of damsAcquiring dam concrete samplesSamples of concrete core... or produced in the laboratory 42. 5 cm2D CT slices of a concrete core 43. References Ribeiro, S ; Paschuk, S ; Swinka-Filho, V ; Schelin, H . Analysis of dielectric breakdown in power cables using 2D and 3D tomography. Insight (Northampton), v. 53, p. 557-561, 2011. Godoi, W C ; de Geus, K ; da Silva, R R ; Filho, V Swinka . Automated flaw detection in X-ray tomography of polymer insulators. Insight (Northampton), v. 52, p. 533-539, 2010. Mendes, R ; Portella, K F ; GODOI, W. C. ; Galvo, J C A ; Joukoski, A ; Martins, P ; Swinka-Filho, V ; de Geus, K ; GALVO, J. C. A. . Determination of crushed stone volume in concrete cores from hydroelectric power plant dams by three-dimensional tomography. Insight (Northampton), v. 51, p. 654-659, 2009. Godoi, W C ; Geus, K de ; Swinka-Filho, V ; da Silva, R R . Volume and surface measurements of flaws in polymeric insulators using X-ray computed tomography. Insight (Northampton), v. 50, p. 554-559, 2008. Godoi, W C ; da Silva, R R ; Swinka-Filho, V . Pattern recognition in the automatic inspection of flaws in polymeric insulators. Insight (Northampton), Inglaterra, v. 47, n.10, p. 608-614, 2005. 44. Prof. Dr. Walmor Cardoso Godoi Universidade Tecnolgica Federal do Paran UTFPR Curitiba - PR e-mail: walmorgodoi@utfpr.edu.br url: http://www.walmorgodoi.com/utfpr