SCAN-IT

The Solution

With SCAN-IT, ROSEN has developed an inspection system for ultrasonic (UT and PAUT) inspection in an immersion tank that can be adapted to a wide variety of inspection tasks and components. For this purpose, multiple motorized axes and accessories offer a maximum degree of freedom while at the same time maintaining precise movement and repeatability. Furthermore, application-specific hardware and software modules are available for system configuration or can be developed and adapted by ROSEN upon request.

The main features of the SCAN-IT product family are an immersion tank made of stainless steel accessible from above and linear axes that automatically scan the test material with ultrasonic sensors depending on the defined inspection task. The basin is usually loaded with the test material automatically by a loading system or manually by the operator.

Typical SCAN-IT applications:

• Railroad axles in the production process
• Bars, billets and profiled material
• Components for the aerospace and automotive industry
• Casting or plate samples for sour gas applications in the oil and gas industry

SCAN-IT main design features:

• Machine frame made of passivated and painted steel designed for rough industry environments
• Water distribution system to supply bubble-free water and prevent accumulation
• Arrangement of linear axes in the Cartesian system
• Inspection carriage with probe arrangement and fine adjustment
• Additional devices (e.g., roller stations and stopper unit) to position and align the test material in the basin
• ROMIS frontend electronics for UT and PAUT applications
• Standard interfaces for industrial environments and Industry 4.0
• IDIP inspection software for configuration, visualization, automated data evaluation and customer interfacing
• Electrical and control equipment (PLC), including mobile operator panel

Specific use cases for SCAN-IT include the following:

Railway Axles

The ultrasonic inspection of pre-machined or finished railroad axles using SCAN-IT utilizes up to two dualinspection carriages with UT phased-array or conventional UT probes. The control and inspection software automatically positions the probe for scanning in a helical pattern. Potential damage and critical inspection areas can be analyzed and are reported in a test log after inspection. A stopper unit, equipped with a rotary encoder, guarantees precise axial positioning and proper detection of the circumferential position during inspection. An optional inspection module is available for normative permeability checks from the end face of the axle.

Steel Samples

In order to test steel material for cleanliness or hydrogeninduced cracks (HIC) with ROSEN’s SCAN-IT system, samples are cut out of plates and exposed to a sour medium containing hydrogen sulfide. In the following process step, they are ultrasonically tested to establish characteristic variables to measure resistance against hydrogen-induced cracking. In preparation for the test, the system operator manually places the prepared samples on the dry sample carrier and defines the layout plan and test parameters using the system software. Subsequently, the test basin is raised, and the samples immersed in the water bath are scanned automatically. ROSEN’s IDIP evaluation software determines the characteristic variables in accordance with the applicable standards and quality criteria. Upon completion of the test procedure, the test basin is lowered, and the samples are dried with an automatic blower.

Round Bars and Billets

Round material, such as aluminum bars, is inspected with phased-array UT probes for internal defects and longitudinal cracks in the surface while the bar rotates in the immersion basin. The probes are mounted on an inspection carriage that moves axially over the test object for inspection. Thus, the bar is scanned in a helical pattern. To reduce the number of uninspected zones at the ends of the bar, the inspection carriage automatically positions and stops over the ends for a full rotation. Data evaluation, report generation and process parameter exchange with a customer system via the integrated Industry 4.0 interface takes place automatically.