Ultrasonic Inspection Device for Fast and Precise Welded Joint Inspections Using Robotics
The advancement of automated inspection technologies has revolutionized the production industry, especially in critical applications like the inspection of welded joints. Spot welds and short weld seams—commonly found in industries such as automotive and manufacturing—demand precise, reliable, and rapid evaluation to ensure structural integrity. The integration of ultrasonic inspection devices, particularly those utilizing Phased Array Technology (PA), has dramatically enhanced the speed, accuracy, and efficiency of robotic-supported inspection systems. The innovative PHAsis inspection systems by RAM Solutions represent a cutting-edge solution for automated, ultrasonic inspection, setting new standards in industrial applications.
Key Features and Advantages
The PHAsis ultrasonic inspection device offers a high degree of precision, designed to meet the demands of modern automated production environments. It provides a complete inspection solution for resistance-welded joints, especially steel and aluminum sheets. Here are the key features that highlight the device’s capabilities:
1. Advanced Imaging Inspection
Using phased array technology, the system captures high-resolution images of the welds in real-time. The ability to display live scans in C-scan format (showing a topographical view of the weld) and D-scan format (providing depth-accurate results) allows operators to assess the quality of the weld from multiple angles. This imaging provides clear, actionable insights into the internal structure of the welds, identifying defects such as porosity, cracks, and incomplete fusion.
2. Precise Measurement Capabilities
The device features 729 virtual probes that ensure ultra-precise measurements, with a physical resolution better than 0.35 mm. Such accuracy is crucial when inspecting small and critical welds, such as spot welds in automotive manufacturing, where even minor defects could lead to significant safety concerns.
3. High-Speed Inspection
The inspection speed of the PHAsis system is another standout feature. With the ability to perform 20,000 ultrasonic measurements per second, it delivers high-resolution inspections at an incredibly rapid pace. This ensures that even in high-throughput production lines, the device can process large volumes of data without compromising on quality. The ability to record more than 700 measuring points (A-scans) per spot weld means that every weld is thoroughly checked for potential defects.
4. Versatility in Weld Inspection
The system can be used for testing resistance welded spots in both steel and aluminum sheets, accommodating a single sheet thickness range from 0.6 mm to 5 mm. This versatility makes the PHAsis system ideal for inspecting a wide range of materials and weld types, from automotive body panels to lightweight aluminum components.
5. Data Storage and Traceability
A key benefit of the PHAsis system is its ability to store all A-scan data recorded during the inspection process. This ensures that the entire inspection procedure is fully traceable, with the option for re-evaluation of results. By correlating the ultrasonic data with destructive testing results, manufacturers can ensure greater accuracy and reliability in quality control.
6. Ease of Use and Minimal Training
The PHAsis device has been designed for simplicity and ease of integration into production lines. With a minimal training time of approximately 4 hours, operators can quickly familiarize themselves with the system, making it an ideal choice for fast-paced production environments where training time must be minimized. The system also offers user-friendly interfaces for managing inspection plans and monitoring inspection equipment.
7. Flexible and Durable Probe Technology
The PHAsis device utilizes advanced probe technology, including fixed rexolite delay paths or flexible water delay paths with membranes, ensuring the best results even on rough or uneven surfaces. The device can be customized with special probes for challenging inspection conditions, such as coarse grain structures or hard-to-reach areas in complex geometries.
8. All-in-One Inspection Management
The device is designed as an all-in-one solution, allowing users to manage inspection plans, monitor the status of inspection equipment, and carry out inspections in “free inspection mode” or according to predefined settings. Whether through one-click presets or customizable parameters, operators can achieve reliable inspections quickly and efficiently.
Optional Mobile Inspection Trolley
For enhanced mobility, RAM Solutions offers an optional mobile PHAsis inspection trolley. This complete workstation can operate without a mains connection, utilizing high-performance exchangeable battery units for long-term operation. This mobility ensures that the inspection system can be used effectively even in locations where a stationary setup would be impractical.
Proven Reliability and Industry Expertise
With over 25 years of experience in spot weld inspection, the PHAsis system has been developed with a deep understanding of industry requirements and challenges. RAM Solutions’ expertise in ultrasonic inspection systems ensures that users benefit from a mature, reliable solution that integrates seamlessly into automated production environments.
Conclusion
The PHAsis ultrasonic inspection system represents a groundbreaking solution for fast, accurate, and reliable spot weld inspections in automated production lines. With its advanced imaging capabilities, precise measurement technology, high-speed performance, and ease of use, it is well-suited for industries that require rigorous quality control, such as automotive and heavy manufacturing. For more information or a demonstration, contact RAM Solutions at 248-299-0525.
