SDI has installed heavy duty bar systems with instrumentation from numerous sources. Multi-zone systems have been installed with proprietary GE multi-channel flaw detectors. Other systems have Krautkramer USPC 2100 instrumentation. The recommended instrumentation is the SDI-2460 flaw detector.
This high speed, high-resolution instrument is designed for industrial on-line applications where features such as the interface gate synchronization eliminate variations due to surface conditions and bar flutter.
The unit can have up to eight sequenced channels each consisting of a pulser/receiver module. Each channel will accommodate four gate modules with rear panel outputs and front panel LED displays indicating the gate condition.
For each channel a flaw gate LED will be illuminated if an echo appears in the gate above the pre-set thresholds. Thickness modules are available if required.
All system functions will be controlled and monitored by the SDI-1830-UTB system control module. This is an integrated suite of software modules running on a rack mount industrial P.C. with an optional touch screen display.
There are four main functions: - 1) Instrument set-up and display, 2) System control, 3) Operator input, and 4) Data logging. The screens can be custom designed for particular applications. Typical screens for each of these functions are shown below. These could be reconfigured as required.
This screen allows each instrument channel to be set up and directs the video and gate outputs from the selected channel to the display scope. At any time the operator can view the A-scan display of any channel by touching that channel number on the screen. All set-ups can be stored and recalled with a file name. Other functions controlled include:
- Instrument set-up; gain, gate position and gate threshold.
- Instrument response monitoring - either the alarm condition, the signal amplitude or the time of flight.
- Multi-channel sequencing to prevent cross talk by sequencing pulsing, gate position and gate width on each pulse.
- Transducer manipulation where motorized transducer positioners are used the positions of each transducer for each material, type and size can be stored as part of the test parameter set-up. (option)
This is the main screen for controlling system configuration parameters and defect location markers when supplied. The inspection helix pitch is controlled as determined by the required defect detection level. The system controller controls the drive speed and helix angle of the system. For more automated systems this module receives input from various sensors on the system and instrumentation and determines a sequence of events based on these inputs. The precise sensor input is determined by the type of test being performed and the options installed. Custom inputs can be accommodated for special functions.
For the variable input levels, both digital and analog, internal comparator logic allows the operator to set high and low thresholds for the quantity being measured. When these thresholds are exceeded the required response can be programmed. An example of this device would be the marking of regions where different types of defect occur.
Other parameters monitored are rotational speed and linear velocity of the bridge. Part diameter can be entered manually or automatically measured.
There are a wide range of programmable controller responses, examples of these are 1) delayed response, for the action of down stream devices, such as paint markers or sorting stations, and 2) defect indication suppression. This is required at or near the end of a bar. It also provides direct operator jog control allowing the system to be reversed to investigate defect indications.