Illustration 1: The Innovation Diploma winners with their diplomas: Steen Neergaard, Peder B. Hansen and Lars Vesth. |
The diploma was handed over to the winning team MM. Lars Vesth, Peder B. Hansen and Steen Neergaard, Division for NDT and Information Technologies, FORCE Institute during the opening ceremony of the 7th ECNDT conference at May 26 in Copenhagen, Denmark.
The prize was given for the development of a complete 3D robot inspection system for efficient and reproducible non destructive testing of components with complex geometry, e.g. node and nozzle welds found in offshore, petrochemical and power generation industries. By combining advanced UT and robot technology with the use of information technology, the team has developed a flexible and portable inspection system based on FORCE Institute's new Modular Scanner System and new ultrasonic data acquisition system P-scan System 4.
Illustration 2: 3D Robot Inspection System overview.. |
By use of FORCE Institutes new Modular Scanner System, a flexible and portable (weight approx. 25 kg) 6 degrees of freedom robot scanner has been developed. The robot control system includes only the new P-scan processor PSP-4 (weight approx. 5 kg) and a small power supply. The desired NDT equipment (e.g. ultrasonic transducer) is mounted at the "TCP" (tool centre point) at the end of the outermost link of the robot.
New P-Scan Data Acquisition System - P-scan System 4
The principal equipment for the ultrasonic examination of complex geometry components is the new P-scan System 4. This examination system provides many new features, which allow the operator to collect very large amounts of ultrasonic A-scan data with attached unambiguous 3D transducer position information and to perform several inspections simultaneously e.g. pulse-echo, time-of-flight, etc.
3D Ultrasonic Simulation and Path Generation
By use of a 3D CAD model of the component geometry the ultrasonic sound propagation in the material is simulated in the UltraSIM simulation module. Based on this simulation and on definition of the desired transducer and inspection volume, unambiguous surface points are created and collected into scanning paths, which are collected into scanning programs.
Generic On-line Scanner Control and Monitoring
Scanning programs are the direct input to the UltraSIM online scanner control module. This module can calculate and simulate Cartesian motion for most ordinary robot configurations. Together with the PSP-4 control unit this module forms the control system and enables the physical robot to follow any defined scanning path in 3D space.
User interference is based on the virtual 3D inspection cell in the CAD system and the motion of the physical robot is monitored real-time on the attached 3D CAD display, that is, the 3D CAD model of the robot is dynamically updated according to the position of the real robot. The current position information of the robot is used in the CAD system for collision warning and avoidance.
During scanning digitised A-scans with unambiguous transducer surface position are recorded by use of P-scan System 4.
3D Reconstruction and Evaluation of Defects
In the virtual inspection environment in the attached 3D UltraSIM system, recorded ultrasonic A-scan data with attached 3D transducer position information are reconstructed in a realistic 3D CAD model of the component geometry. Reconstructed data can then be seen as voluminous 3D indications coded visually due to amplitude or image (direct/reflecting wave). An attached 2D section view function enables data specified by a 2D cutting plane to be displayed as ordinary 2D images and a 3D stereo view facility adds enhanced 3D effect to the 3D viewing mode. In addition various characterization facilities make it easy to measure 2D and 3D length, height and position of indications.
Illustration 3: AIR-1e robot scanning open test block. |
The 3D Robot Inspection System is applicable to most areas where components with complex geometry surfaces have to be inspected with UT, ET and VT. The system concept allows inspections to be carried out where conventional NDE inspection systems (automatic XY type scanners, manual inspection, etc.) cannot accomplish the inspection task, e.g. due to geometry or harsh environment such as underwater inspection of offshore, petrochemical or nuclear components.
For further information on the 3D inspection system
components and applicability please contact:
Lars Vesth
FORCE Institute
Division for NDT and Information Technologies
Phone: +45 43 26 70 00
Fax: +45 43 26 70 11
E-mail: lv@force.dk
WWW: http://www.force.dk; http://www.ultrasim.dk; http://www.p-scan.dk