KD-Check Liquid Penetrant Inspection Systems · Automated Liquid Penetrant Inspection with high...
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KD-Check Liquid Penetrant Inspection Systems Automated Liquid Penetrant Inspection with high Throughput and high Process Reliability KARL DEUTSCH Authors Paper P33: Stephan Robens, Dr. Ralf Wagner, Dr. Oliver Goerz, Dr. Wolfram Deutsch, DACH-Conference Salzburg, Austria, May 2015 Characteristics: • Fluorescent inspection of automotive and power generation components made of stainless steel and titanium, a wide variety of components is testable • Modular system concept • Components transport in baskets (0.5 m x 0.5 m), max. 30 kg per basket, manual basket transportation on rollers • Method according to EN ISO 3452: Type I, Method A, Form a • Sensitivity level 2 or level 3 (two optional ways through the system) • Electrostatic unit for dry developer application • Examination cabin with 2 positions, evaluation with UV-LED large area lamp • Optional used wash water recycling via active carbon filter columns • Siemens control of process parameters with order-related data storage Characteristics: • Fluorescent liquid penetrant testing of forged automotive motor components • Method acc. to EN ISO 3452: Type I, Method A, Form a • 10 components in one workpiece holder • Transport via roller tables • Pneumatic movement of the workpiece holders • Simple linear transport concept (almost no lifting or lowering of components) • 3 minutes cycle time with buffering of longer lasting process steps • PLC process control and parameter documentation • Optional automated re-dosage of testing agent • Wash water recycling via filtering columns (cost reduction) and energy efficient dryers • Inspection with UV-LED large area lamps Characteristics • Testing system for 4500 parts per day • Most stations in duplicated design • Fluorescent testing • Component transport in suspended workpiece holders, each for 24 parts • Electrostatic dry developer application • Visual examination with mobile UV-LED lamp Process control • SIEMENS electrical control with touchpanel • Penetrant level measurement • Temperature control of the penetrant tanks • Temperature regulation for the four ovens • Time-controlled process steps via stop watches, process sequence visualization with signal lights • Position monitoring of workpiece holders for each station • Doubly active carbon filter columns Stations of the system A: Component feeding B: Pre-cleaning (waterbath with additional water nozzles) C: Dryer 1 D1: Penetrant dip tank (level 2, medium sensitivity) D2: Penetrant dip tank (level 3, high sensitivity) E: Draining station (one tank per way, penetrant recirculation to the original tank) F: Penetrant removal with water and hand-gun (after lowering into stainless steel tank and expanding the lateral protection doors) G: Dryer 2 H: Electrostatic developer application (with exhaust in rear, lateral protection doors) I: Visual examination under UV light in a testing cabin Stations of the testing system A: Component feeding B: Penetrant application (pneumatic lowering into dip tank) C: Draining station and recirculation of excess penetrant D: Penetrant removal via water-jet tunnel E: Buffer F: Dryer (circulated warm air) G: Dry developer application in a vortex chamber H: Developing line I: Visual examination J: Used wash water recycling (doubly active carbon filtering column) Stations of the testing system A: Pre-cleaning B: Dryer C: Penetrant application D: Penetrant drainage E: Penetrant removal F: Dryer G: Electrostatic application of dry developer H: Visual examination under UV light in darkroom (cabin) U-shaped testing system, component transport in stainless steel baskets Linear component transport in workpiece holders with 3 minute cycle time Oval crane runway for workpiece holder transportation, right: examination in cabin Semi-Automated System for Castings Fully Automated Testing System for Automotive Forgings Semi-Automated Testing System for Aluminium Forgings with oval Crane Runway A B1 D1 H B2 D2 C1 C2 E1 E2 F1 F2 G A B C D E J I G F E H
Transcript of KD-Check Liquid Penetrant Inspection Systems · Automated Liquid Penetrant Inspection with high...
KD-Check Liquid Penetrant Inspection SystemsAutomated Liquid Penetrant Inspection with high Throughput and high Process Reliability
KARL DEUTSCH
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Authors Paper P33: Stephan Robens, Dr. Ralf Wagner, Dr. Oliver Goerz, Dr. Wolfram Deutsch, DACH-Conference Salzburg, Austria, May 2015
Characteristics:• Fluorescent inspection of automotive and
power generation components made of stainless steel and titanium, a wide variety of components is testable
• Modular system concept• Components transport in baskets
(0.5 m x 0.5 m), max. 30 kg per basket, manual basket transportation on rollers
• Method according to EN ISO 3452: Type I, Method A, Form a
• Sensitivity level 2 or level 3 (two optional ways through the system)
• Electrostatic unit for dry developer application
• Examination cabin with 2 positions, evaluation with UV-LED large area lamp
• Optional used wash water recycling via active carbon filter columns
• Siemens control of process parameters with order-related data storage
Characteristics:• Fluorescent liquid penetrant testing of
forged automotive motor components• Method acc. to EN ISO 3452: Type I,
Method A, Form a• 10 components in one workpiece holder• Transport via roller tables• Pneumatic movement of the workpiece
holders• Simple linear transport concept (almost
no lifting or lowering of components)• 3 minutes cycle time with buffering of
longer lasting process steps• PLC process control and parameter
documentation• Optional automated re-dosage of testing
agent • Wash water recycling via filtering columns
(cost reduction) and energy efficient dryers• Inspection with UV-LED large area lamps
Characteristics• Testing system for 4500 parts per day• Most stations in duplicated design• Fluorescent testing• Component transport in suspended
workpiece holders, each for 24 parts• Electrostatic dry developer application• Visual examination with mobile UV-LED
lamp
Process control• SIEMENS electrical control with touchpanel• Penetrant level measurement• Temperature control of the penetrant tanks• Temperature regulation for the four ovens• Time-controlled process steps via stop
watches, process sequence visualization with signal lights
• Position monitoring of workpiece holders for each station
• Doubly active carbon filter columns
Stations of the systemA: Component feedingB: Pre-cleaning (waterbath with additional water nozzles)C: Dryer 1D1: Penetrant dip tank (level 2, medium sensitivity)D2: Penetrant dip tank (level 3, high sensitivity)E: Draining station (one tank per way, penetrant recirculation to the original tank)F: Penetrant removal with water and hand-gun (after lowering into stainless steel tank and expanding the lateral protection doors)G: Dryer 2H: Electrostatic developer application (with exhaust in rear, lateral protection doors)I: Visual examination under UV light in a testing cabin
Stations of the testing systemA: Component feedingB: Penetrant application (pneumatic lowering into dip tank)C: Draining station and recirculation of excess penetrantD: Penetrant removal via water-jet tunnelE: BufferF: Dryer (circulated warm air)G: Dry developer application in a vortex chamberH: Developing lineI: Visual examinationJ: Used wash water recycling (doubly active carbon filtering column)
Stations of the testing systemA: Pre-cleaningB: DryerC: Penetrant applicationD: Penetrant drainageE: Penetrant removalF: DryerG: Electrostatic application of dry developerH: Visual examination under UV light in darkroom (cabin)
U-shaped testing system, component transport in stainless steel baskets
Linear component transport in workpiece holders with 3 minute cycle time
Oval crane runway for workpiece holder transportation, right: examination in cabin
Semi-Automated System for Castings
Fully Automated Testing System for Automotive Forgings
Semi-Automated Testing System for Aluminium Forgings with oval Crane Runway
AB1
D1
H
B2D2C1 C2 E1 E2 F1
F2
G
A B C D E
J
IGF E H
![Liquid Penetrant Testing[1]](https://static.fdocuments.in/doc/165x107/577ccf951a28ab9e78901793/liquid-penetrant-testing1.jpg)
