Automated Ultrasonic Inspection Improves Quality and Benefits Economy in Welding Workshops

摘要

Advanced automated ultrasonic systems coupled to intelligent developed scanners have proven to optimize on all important parameters within inspection, regardless if it replaces the manual process or replaces for example X-ray. Replacing the manual ultrasonic inspection with automated equipment in manufacturing units, improves both the quality of the inspection and the quality of delivered products. At the same time, the automated inspection is a significant economical benefit for the manufacturer. As an example we will highlight the benefits for the manufacturer of wind turbine towers, usually producing many meters of weld per day. Time savings of 8 - 10 times compared to the manual examination work is possible, and at the same time the quality work is improved significantly. The huge time saving achieved through automated ultrasonic inspection is possible with the most advanced automated ultrasonic systems on the market, controlling intelligent probe set-up including several transducers scanning simultaneous with TOFD and Phased Array techniques. Coupled to smart programmable scanner devices, scanning speeds of more than 100 m/hour is possible, even in welding workshops. Unlike manual inspection, all parameters such as speed and data recording are precisely controlled with the automated inspection equipment. Advanced automated ultrasonic systems have also special features to lock parts of the software to avoid, that fatal human errors are introduced. The manual inspections are controlled only by the inspector carrying out the inspection. Programming human beings to make movements of for example maximum 150 mm/sec with an overlap of maximum 10% is difficult, and most inspectors are confident that they can do inspections faster than that, and still perform excellent. In fact, directly asked, most inspectors admit that they perform inspections with minimum twice the speed dictated by the procedure. Examination of a 15 m long and 80 mm thick circumferential weld takes about 12 minutes with the automated equipment, while it with conventional manual ultrasonic, according to EN 17640, should take the operator minimum about 128 minute. This paper describes implementation of advanced automated ultrasonic inspection in the workshop, and highlights the technical, economical and human benefits achieved by replacing manual ultrasonic inspection with intelligent automated inspection equipment.