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Tower Systems

SDI-5750 Independent Tower Through Transmission 3D Scanning Ultrasonic System


SDI-5750 System Overview

The SDI-5750 is a full feature high performance 3D curve scanning UT system designed for incorporation into airframe Lean Manufacturing environments. It incorporates all the features of a large scale fixed gantry system such as the SDI-5410, into a relocatable unit.

The system is designed to inspect a complete range of part geometries, such as aircraft control surfaces, wings, doors etc in addition to highly contoured fuselage and cabin components.

The motion control, data acquisition and instrumentation components can be installed in a system control room, or operated from a shop floor console. The system is based on modules widely used in SDI's product range.



All components/modules used in the system are designed and manufactured in-house by SDI in their Camarillo, California facility.

Note: This specification is for a typical SDI-5750 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.


SDI-5750 System Features:

  • Scan speed up to 35 ips.
  • Linear Amplifier UT for greater defect amplitude resolution.
  • Log Amplifier UT for greater dynamic range.
  • Simultaneous dual channel through-transmission (TTU) and pulse-echo(PE) providing four data files from one scan ; one PE from each side and two TT at different gain levels.
  • Four pulser selections - high power spike (1000v), high resolution spike(400v), tone burst and square wave.
  • Optional coordinated parameter control - instrument parameters such as gain and gate position can be built into a scan plan as additional coordinated ''axes'' changing at rep rate speeds.
  • 130 dB dynamic range.
  • 40dB Distance Amplitude Correction.
  • Multi-processing allowing scans to be analyzed while they are being acquired.
  • Auto-normalization and auto-teach of scan profiles.
  • Complex curve following in any orientation, with 3 point part location.
  • Optional full waveform capture usually used with mini-scan described below.
  • Return to defect - automatic return to ROI identified by the operator.
  • Mini-scan - automatic re-scan around ROI for defect analysis.
  • Absolute encoding eliminating the need for frequent homing even after activation of collision switch or E-stop.
  • 3D to 2D image mapping for accurate flaw sizing.
  • Optional automated pen marking controlled from image analysis station.

Mechanical Configuration

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 independent towers are mounted on a rigid platforms running on heavy duty ball shafts with proprietary high endurance bearings. The Y axis arms are designed to accept a range of interchangeable gimbal assemblies for various applications. The standard extended reach gimbal/gimbal unit is used for the majority of applications where access is not a problem.

Where there are restrictions, the compact gimbal/swivel unit is more appropriate. The axes of motion provided on the system are shown in the table below:




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.


AxisDescriptionRangeSpeedResolutionAccuracy
XPrimary axis along the frame. d.c. servo drives.24 ft.24 in/sec.001 in..004 in/ft
Z1, Z2Vertical column rack and pinion drives. d.c. servo drives.120 in.15 in/sec.001 in..004 in/ft
Y1, Y2Lateral arms. Rack and pinion drive with d.c. motors and resolvers.68 in.12 in/sec.001 in..004 in/ft
A1, A2Gimbal in Y, Z plane+/- 90 deg30 deg/sec.01deg0.01deg
B1, B2Gimbal in Y, Z plane+/- 90 deg30 deg/sec.01deg0.01deg

Linear Drives

For all linear ways, heavy duty helical rack and pinion drive provides precise positioning and encoder feedback. The independent tower design also simplifies maintenance and repair as the drive components for all axes are accessible from ground level.

The linear ways for Z 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 with safety braking . All drives are closed loop d.c. with encoders/resolvers.


Gimbal Drives

The gimbals are harmonic drive d.c. 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.


Control Console

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.


Electrical Configuration

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:


Instrumentation

The system can be supplied with any third party systems instrument such as the Socomate USPC3100-2, two channel unit. When installed with the SDI sequencer unit, the system can be configured to be able to provide simultaneous pulse echo from each side together with two through transmission tests, resulting in the acquisition of four channels of data in a single scan.

A range of auxiliary instrumentation can be provided to aid in the inspection of the more complex highly attenuative lay-ups. This will include log amplifiers, pre-amplifiers, and tone burst pulsers.


Motion Control

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.



Installation

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.


Training

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.


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