1 Robot-based real-time ultrasonic tomography for industrial NDT applications Dr. Andrey Bulavinov I-Deal Technologies GmbH
2 Content I. Introduction of I-Deal Technologies GmbH I-Deal Spin-Off of Fraunhofer-IZFP II. Technology: Ultrasonic tomography based on Sampling Phased Array Technology Spatial calibration of robot and high-resolution position tracking for III. Applications: Examples of successful implementation of automated tomography systems for industrial applications
3 Company Profile I-Deal Technologies is a Spin-Off company of Fraunhofer Society with scientific background, which has developed a novel UT technology. We are introducing a new quality of ultrasonic testing. I-Deal Technologies is considered to be a technological leader in the UT market I-Deal Technologies GmbH is an innovative Company that offers their advances products together with strong R&D-Partner Fraunhofer-IZFP Production and development in Saarbrücken
4 Systems and components IDeal System Mobile and stationary ultrasonic analysis systems IDeal MIRA Ultrasonic systems for concrete testing IDeal Viewer Software for 3D visualization and analysis of ultrasonic inspection results IDeal Components Motion control, UT hardware, Software, PA transducers, manipulators
5 Services IDeal Development Development of system components according to customer requirements IDeal Services Inspection services with Sampling Phased Array Systems Maintenance and repair services Spare part services
6 Ultrasonic testing in the course of time Yesterday Today Lack of fusion
7 Defocused transmission State of the Art. Conventiona Phased Array Sampling Phased Array Wellenfront Fokus Wellenfront θ Schwenken Fokussieren
8 Phased Array Principles Medicine: Wave front Focus NDT: θ Steering Focusing
9 X-Ray vs. UT X-Ray testing Quantitative? Ultrasonic testing Flaw type http://www.volpe.dot.gov/ Flaw size Flaw orientation www.geinspectiontechnologies.com
10 Ultrasonic testing Quantitative
11 Introduction: technologic components Ultra-fast acquisition and transfer of UT data Real-time image reconstruction by efficient computing 3D visualization of UT data Automatic flaw detection and sizing
12 Sampling Phased Array
13 Sampling Phased Array Principles Defocused transmission Wave front
14 Sampling Phased Array Principles Conventional Phased Array 2 x L Sampling Phased Array 2 x L L L Sector Image
15 3D Imaging by Sampling Phased Array Building of synthetic aperture Probe aperture
16 Sampling Phased Array Quantitative 3D Imaging Quantitative tomographic representation of inspection volume
17 Sampling Phased Array: Application fields
18 Sampling Phased Array Plattform
19 3D Inspection planning
20 3D UT tomography of thick-walled pipes Customer: TÜV SÜD Branch: power generation Task: Automated defect sizing in welds Customer advantage: quantitative UT, exact flaw evaluation
21 3D UT tomography of thick-walled pipes B scan pores
22 3D UT tomography of thick-walled pipes Lack of fusion
23 Quantitative crack evaluation in austenitic weld 0 4.4 10 4.4 mm 20 6.2 mm 6.3 26.9 30 Metallography Micrograph 40 50 62.5 75 87.5 100 Ultrasonic image
24 Ultrasonic testing of steel slabs Customer: ThyssenKrupp AG Branch: steel industry Inspection Task: Production testing of steel slabs Customer advantage: production integrated quality control R1 R2 Liquasions
25 Ultraschallvermessung von Tieflochbohrungen Branch: automobile industry Task: Full automatic measurement of deep hole positions with cycle time 20 sec. Customer Profit: Reliable procedure with high precision, staff savings,
26 Mobile system for pipe inspection Branch: Oil and gas Task: automated inspection of weld joints throu the cap Customer Profit: Innovative inspection technique and time saving inspection machine Crack
27 Fast inspection of lightweight composite materials Scanner path PA probe 3D volume Automatic inspection set-up for fast testing of CFRP components
28 Fast inspection of lightweight composite materials Radius testing
29 Fast inspection of lightweight composite materials Radius testing
30 Fast inspection of lightweight composite materials Customer: BMW Branch: Automobile industry Task: Development of an Sampling Phased Array System for fast CFK testing Customer profit: modern ultrasonic analysis tool with quantitative flaw evaluation
31 Robot-based testing of CFRP components Ultrasonic non-destructive testing of CFRP components is the most widely used industrial testing technique The newest trend of the ultrasonic non-destructive evaluation is 2D and 3D imaging of the inspection volume by means of tomographic reconstruction techniques (SPA, FMC, Total Focusing, IWEX) with quantitative evaluation of inspection results. The biggest practical handicap of the ultrasonic flaw detection is the irregular / complex shape of the inspection objects due to hindered coupling of ultrasound into the component. Profiling and taking into account geometry of the inspection object while ultrasonic testing is a challenging task with significant application potential.
32 Inspection procedure / work flow 1) Obtaining 3D CAD of inspection object 2) Simulation of scanning path for robot aimed inspection 3) Inspection and evaluation 3D CAD model Scanning path 3D CAD model with acquired ultrasonic data
33 Obtaining 3D CAD model of the inspection object
34 Simulation of scanning path for robot aimed inspection
35 Robot-aimed data acquisition in Sampling Phased Array mode
36 Real-time surface profiling and volume reconstruction by Sampling Phased Array Transducer Object surface Object
37 Real-time surface profiling and volume reconstruction by Sampling Phased Array Transducer Object surface Object
38 3D representation and automated evaluation of inspection results Representation of inspection results on the CAD-model of the tested component Automated evaluation of the indications Geometric position related to the reference point (XYZ) Geometric dimensions ( X, Y, Z) 9 mm 6 mm 3 mm
39 Robot-aimed inspection set-up for Automated robot-aimed inspection manipulator Tactile calibration system CAD-model based inspection procedure Real-time 2D / 3D representation of the inspection results Automated evaluation according to pre-set acceptance criteria
40 Testing of composite componets
41 Testing of fusion reactor components with SPA 3D Darstellung der Prüfergebnisse Customer: NIIEFA Branch: Atomic energy / fusion reactor Customer profit: Automated inspection of objects with arbitrary shape
42 Radiography and X-ray tomography systems on the base of smallsize electron accelerators X-ray tomography principle Object Source Detector
43 Radiography and X-ray tomography systems on the base of smallsize electron accelerators Application field: Testing of thick-walled objects Electron acceleration energy: from 2.5 to 14 MeV Object thickness (steel): up to 500 mm Focal spot size: 300 m x 300 m
44 Radiography and X-ray tomography systems on the base of smallsize electron accelerators
45 Radiography and X-ray tomography systems on the base of smallsize electron accelerators
46 Conclusion 1. Sampling Phased Array (SPA) is an advanced ultrasonic technique that in combination with modern robotics allows solving of complex inspection tasks. 2. The presented practical applications show the great advantages of ultrasonic tomography by reliable quantitative high speed 3D imaging. 3. Fast inspection systems can be used for off-line analysis of safety-relevant components as well as for automated in-line testing in the production process
47 Thank you for your attention!