New Gate Technologies Newsletter—July 2011
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Moving from Random Sampling to 100% Inspection
Transitioning from a manually-operated NDT system to an automated solution can be both challenging and very rewarding. Why would a company want an automated system? The answer is two-part: reliable data and increased ROI. Collecting and managing accurate information about each part in an easy-to-use tool is critical to efficiency, and an efficient line means a profitable line. Manual systems typically take longer and can only sample a random selection of parts. Of that random selection, only small areas are tested, resulting in few data points which means lost time and money. While the initial investment in an automated system may seem high, in many cases a substantial return on investment is possible within a few months.
The Project
Recently, a customer who was performing manual pulse echo profiling of diesel particulate filters (DPFs) approached New Gate Technologies about automating their process. Some of the problems the customer had with the manual process were:
- Long cycle inspection time (10-minutes per piece, at best)
- Partial scans of the work piece—they wanted full piece scans
- Random sampling—they wanted to inspect every piece
- 9–18 data points—they wanted more information about each piece
The first step we take in evaluating a process for automation is asking this question: can we create an automated solution that produces repeatable, reliable, accurate results, and effectively manages the data while achieving the desired ROI? Sometimes the answer is no. Every process can be automated but the cost of the system or components can become prohibitively expensive. The prevailing thought within our customer's company was that the process could not be automated because 1) it was cost prohibitive and 2) a previous in-house attempt had failed.
The Process
The engineers and designers at New Gate Technologies tested various methods, evaluated design criteria to automate the test methods, collaborated with a UT probe supplier to build a test bench, and proved a test methodology that could be automated. The result of the detailed evaluation led us to believe that a successful, affordable automation system was possible. After much consideration, we proposed an automated phased array UT defect detection application for substrate inspection utilizing a custom designed probe and proprietary dry coupling method.
The main challenges in the building phase for this system were:
- Developing a test method to scan parts. There was no off-the-shelf probe available to scan parts up to 15" in diameter. We partnered with Olympus NDT to design a custom probe with the proper mounting, size, and cable exit points, with 128 elements.
- Developing a test process that could be automated. We had to address how to couple a large custom probe to the part. This was accomplished by building a test fixture to prove out a proprietary dry coupling method. The method was then scaled up in a production design that included both the custom probe and the full size dry coupling chamber.
- Integrating the test method into the automated UT process. It was necessary to make the system easily adaptable to various size and shaped parts. Then provisions for loading, positioning, processing, and unloading parts were designed into the unit. Critically important aspects were: head offset, probe location, and requirements for making each step accurate and repeatable, in addition to presenting the scanning mechanism with proper speed.
- Developing supporting software (data collection, system interface, and factory interface). This included GUI design for the display of data and images, along with designing a way for machine operators to setup and configure the UT scanning recipes for each part.
- Integrating the system into a factory setting that implements motion and control systems for part location, head location, safety, and human interface considerations.
- Developing extensive testing and inspection methods for defect detection, pass/fail criteria, customer specifications, and identifying variables in the inspection data.
The Results
The final automated phased array UT solution was a huge success for the customer. Their inspection cycle time was reduced to 45 seconds (down from 10 minutes), the new system provided 100% inspection capacity with full scans of each work piece, and it collected and managed 10,000 data points for each piece. The customer reported a positive ROI within the first year. For the first time the customer was able to offer 100% automated inspection to their customer.
Recommendations
Automated solutions in NDT systems can bring increased efficiency and production, but anyone considering automating a manual process should partner with both equipment designers and component suppliers in the discovery phase. The purpose of this collaboration is to gather as much information as possible to accurately evaluate the feasibility of the project. Whether or not automation is possible depends on your ability to 1) produce repeatable, reliable, accurate results, 2) effectively manage the data produced and 3) achieving the desired ROI.
Contact Application Engineering at New Gate Technologies if you have any questions about automating your inspection process: 406-548-4320 or dbrekhus@newgatetech.com.
Servo vs. Pneumatics: What’s Best for Your Motion Application?
When industrial systems require motion, mechanical designers must research and choose between a servo or pneumatic application. The decision process starts by considering these questions: Does the movement require precise placement? How fast does it have to move? What will it cost? Servos are fast and precise but usually carry significant purchasing and repair costs. Pneumatic motion is typically low-cost and very reliable, but requires more parts and operates slower than a servo system. Let's investigate the details of each option.
Servo drive applications allow for fast and accurate results. They are frequently coupled to a gear-reducing head or actuator with an incline plane type of mechanical advantage. This offers the servo motor and controller a very precise platform to accurately position the load it is moving. The machine's PLC or PC controls every part of the servo, ensuring flexibility and ease of use. With a few simple code changes, an operator can quickly adjust to changing conditions or loads, move the servo into any position, or alter the rate of acceleration and deceleration. Servos are an amazing invention! So why doesn't every system use one? All of this flexibility and ease of use comes at a price, which is sometimes prohibitively expensive.
Servo systems generally cost between $3000–$7500 per motor, depending on the application, and usually need qualified technicians for repair. They also require an in-depth understanding of the software's programming language, and can take several weeks to integrate into a design. If your plant can bear higher costs and longer integration time, the results will be worth it.
The alternative option is pneumatic motion, which uses air cylinders and rotary actuators to hold or move machinery. The process forces compressed air into a chamber behind a piston, generating a tremendous amount of power. Air cylinders can accelerate quickly, and are especially suited for high-speed repetitive motions. Deceleration, however, is a challenge because inertia and pressure tend to take over. Slowing air cylinders down usually requires shock absorbers or bumpers to control shock loads. Adding components like shock absorbers not only adds cost to the design, but is another part that can require adjusting or could possibly malfunction. Low cost is the main benefit of pneumatic motion. Systems usually cost around $50–$1000, making them an attractive choice for many plants.
Designers who are deciding between servo and pneumatic applications should start by considering what they need the system to do and how much they are able to spend. Servo systems offer great performance and speed, but come at a high cost. Pneumatic systems, less expensive than servos, can consistently accelerate in applications that perform the same motion over and over, but require shock absorbers or bumpers for deceleration. Your application and budget may lead you to a pneumatic system, but we often prefer servos because of their speed and accuracy. Review your budget, your application, and you will quickly see which choice is right for you.
President’s Letter
Dear Friend of New Gate Technologies,
With the globalization of so many different initiatives, the last few years have presented many challenges for all of us. The industry has seen such rapid change that we've had to move quickly and decisively in order to adequately address the demands of the market. Needless to say, we've been busy.
Over a year ago, we at New Gate Technologies decided that we needed a real, tangible system for handling customer service needs. The result was a comprehensive asset-based support tool which enables communication between our customers and our service technicians about any of the customer's systems. This web-based support system called AIM (Asset and Incident Management), allows any customer, anywhere in the world to communicate with our support staff 24 hours a day, 7 days a week.
In January of 2011 we began development on a cost effective solution for automated inspection of automotive and diesel catalysts and filters. We knew there was demand for our inspection equipment, but we also knew there were factors that made automated inspection cost prohibitive. Our redesign effort resulted in what we call the 88 Series and the 1520 Series inspection centers. These systems allow for any number of inspections at a price in line with customers’ needs for low-margin, high-volume automotive inspection applications. Our 1520 Series inspection centers provide comprehensive inspection on parts up to 15" (381mm) diameter by 20" (508mm) tall while the 88 Series is designed for smaller substrates up to 8" (203mm) diameter by 8" (203mm) tall.
We've been busy on other exciting projects too. This year we rolled out our 4th generation ultrasonic inspection center for diesel and gas filters and we improved our design and documentation processes to better communicate with the user on critical issues. Our efforts have been well-timed and well-received, so we know we're on the right path. These kinds of changes are never easy and they require dedicated people to exceed expectations. We have those people and the confidence to solve future market challenges head on.
Thank you for taking the time to look over our newsletter. I hope it's informative, interesting, engaging and gives you a small snapshot of who we are and what we are all about. Please don't hesitate to give us any feedback.
Sincerely,
Eric Pierson
President/CEO
New Gate Technologies
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