SDI-5720 System Overview
The SDI-5720 is a low cost high performance UT system designed for incorporation into airframe Lean Manufacturing environments. It incorporates the features of a large scale fixed gantry system such as the SDI-5410, into a compact floor standing unit.
The flexible design allows the system to be supplied configured for the inspection of flat panels, and field upgraded, when required, to perform complex 3D scans.
In full 3D scanning configuration, the system is designed to inspect a limited range of part geometries, such as aircraft control surfaces, wings, doors etc that are too highly contoured to be regarded as flat, but not so contoured as to require a full gantry system.
Accordingly, it is possible to reduce size, complexity, cost and installation requirements, while maintaining performance. In addition, the inherent rigidity of the structure when compared to all but the largest gantry systems allows higher speed scanning with more precise transducer positioning.
Advances in computing and motion control technology mean that the air-conditioned mobile control consoles provided with the unit out perform many of the permanent control room installations associated with larger gantry systems.
Note: This specification is for a typical SDI-5720 Inspection System and is for information only. The details may differ significantly from those proposed for specific customer requirements. The specification provided in the Statement of Compliance and formal quotation supersedes this document.
The system is turnkey, stand alone and fully self-contained. The mechanical configuration is outlined in the attached concept drawing. All support frame members are welded box section.
The frame is mounted on a rigid platform fitted with water containment and recirculation components. The system is movable and when in position it is possible to anchor the system to the ground for additional rigidity.
The axes of motion provided on the system are shown in the table below: Typical ranges are given. These will vary according to customer requirements.
|X||Primary axis along the frame. 3 phase brushless d.c. servo drives with resolver.||144 in.||20 in/sec||.001 in.||.004 in/ft|
|Z1, Z2||Vertical column rack and pinion drives. 3 phase brushless d.c. servo drives with resolver.||60 in.||8 in/sec||.001 in.||.004 in/ft|
|Y1, Y2 (Motorized on 3D version only)||Lateral arms. Rack and pinion drive with brushless d.c. motors and resolvers in oil filled waterproof housing. Column spacing and Y axis reach accommodate a part with overall thickness/chord of 12 in.||18 in.||12 in/sec||.001 in.||.004 in/ft|
|Delta X (Option for complex curves)||Mounted on a single Z axis column.||18 in.||30 deg/sec||.01deg||.004/ft|
|A1, A2 (Motorized on 3D version only)||Gimbal in Y, Z plane||+/- 90 deg||30 deg/sec||.01deg||0.01deg|
|B1, B2 (Motorized on 3D version only)||Gimbal in Y, Z plane||+/- 90 deg||30 deg/sec||.01deg||0.01deg|
For all linear ways, heavy duty rack and pinion drive provides precise positioning and encoder feedback. The frame is an inverted bridge design with both towers mounted onto the same bridge frame.
This has the advantage of maintaining precise alignment in the X direction. The inverted bridge also simplifies maintenance and repair as the drive components for all axes are accessible from ground level.
The linear ways for Z, Y and delta-X axes are precision stainless steel, heavy duty, V rails. These are also fitted with precision rack and pinion drives.
The Z axis carriages are counter balanced. All drives are closed loop d.c. with encoders/resolvers.
The gimbals are direct drive three phase brushless servos with integral high precision resolvers. The units are housed in oil filled stainless steel enclosures. The squirter is attached to the gimbals by a magnetic mount.
The mobile control console can be positioned anywhere within reasonable distance from the system. Current SDI systems have similar remote consoles up to 80 ft. from the scanner.
It is fitted with two 19 inch monitors linked in the Windows operating environment to allow windows to be dragged from one screen to the next, or expanded over two screen.
The console requires a single 110V 60 Amp single phase supply. SDI will install the necessary transformers to achieve this from the customer's supply.
The console houses all the computing, drive and instrumentation components required to operate the system. The enclosure includes a filtration and refrigeration unit.
The electrical configuration describes the components and interconnections for the motion control, drive, instrumentation and data acquisition sub systems. The majority of the components are housed in the system console. All system components meet applicable US and International safety codes.
Apart from the very low current ultrasonic signals, no voltages greater than 70 volts are present anywhere on the system outside the control console. The electrical layout is shown below:
The system is supplied with the SDI 2460-4, two channel systems instrument. This is a modular, multi-channel flaw detector comprising pulser, receiver, flaw gate and thickness modules.
The unit will be configured to be able to provide simultaneous pulse echo from each side together with two through transmission tests. A range of auxiliary instrumentation can be provided to aid in the inspection of the more complex highly attenuative lay-ups.
This includes log amplifiers, pre-amplifiers, and tone burst pulsers. Details of the SDI 2460 are as follows:
High resolution, two channel, fully programmable ''Tank Top'' flaw detector for use with industrial immersion facilities.
Features switchable pulser voltage, frequency, gain and calibrated attenuation.
Flaw and thickness gates with initial pulse or interface triggering.
8 segment DAC module. Range 37dB
Rectified video and r.f. outputs are provided together with external/int sync and sync out.
Selectable voltage and damping
High Power 100-1000V
High Resolution 50-300V
Rep Rate 0.5-5kHz. Per channel
Selectable Pulse-echo/Through transmission.
Switched Frequency 1, 2.25, 5, 10 and broad band. 1-25Mhz
Gain:- 97 dB. dynamic range
Attenuation 1-127dB in 1dB steps
Flaw Amplitude and Thickness
Main Pulse/Interface sync
Stepless gated r.f.
Flaw alarm logic.
Proportional analogue 0-10V.
A-scan display module:
Provides real time A-scan display
A scan printout.
The motion control is provided by the SDI-1830 MasterScan advanced controller. Designed specifically for ultrasonic applications, it features ultrasonic functional axes and scripted scan plans. This means that complex motion control and acquisition activities unique to ultrasonic inspection techniques are available to the operator through simple commands using ultrasonic terminology. The operator can construct complex scans by chaining together individual motion commands, scan plans and instrument set-ups. Full details of MasterScan are given in the data sheet. Some of the key features are:
- Functional axes using standard UT terminology
- Import/Export of scan plans to CAD programs
- Automated normalization
- Auto teach of scan plans
- Integrated instrument control coordinated with the motion along a scan trajectory
- Scripted scan plans
- Chained scans
- Dual independent search tubes performing different scans simultaneously
- Stop on defect
- Return to defect
- Display of scan progress and time to finish
- Variable turntable rotation to maintain constant surface speed with changing diameter
Acquisition / Analysis
The system is supplied with the latest SDI-WinScan multi-tasking acquisition and analysis package designed for high throughput production applications. A technical description of the features and benefits of this high performance industrial package is attached. Some of the key features are:
- High-speed pan and zoom through entire data file
- High speed, high quality 1:1 plotting of all or selected areas of the data file
- Scan comments stored with the data file
- Multi-channel operation
- True multi-tasking to allow scanning, plotting and viewing of stored files to be performed simultaneously without a reduction in speed
- Numerous analysis features such as histograms, in dB and linear scales, cluster analysis
- providing automatic defect identification, image smoothing and filtering with operator defined kernels
- Full Waveform Capture with B-Scan
Another time saving feature of the fully integrated motion control and data acquisition package is the ability to perform mini-scans. Areas of interest can be tagged on the data file and the system will automatically drive back to them and re-scan the area using selected defect evaluation scan parameters such as full waveform capture.
The system will be fully assembled and made operational at the SDI facility in Camarillo for customer buy off. The Acceptance Test Procedure (ATP) will be carried out using the test samples supplied by the customer. SDI will address any items requiring rectification prior to authorization for shipment by the customer representative. Upon receiving approval, SDI will dismantle, crate and ship the system. SDI will carry out site preparation prior to the arrival of the system. The system will then be assembled and made operational on site. The ATP will then be repeated. The system timeline is attached.
SDI provide a comprehensive training program including 5 days training of personnel in the operation and routine maintenance of this equipment. This training will take place either at the SDI facility or at the customer site after installation.