An upgrade of an immersion phased array system has been completed at a composites manufacturer in Malaysia. The system was supplied by Midas in 2013 but was never commissioned. It incorporates 6 motion axes and originally had an Omniscan phased array instrument. The upgrade involved replacement of several of the sub-systems, including the A/B manipulator, Y axis bearings, phased array ultrasonic instrument and motion control / imaging software. The USL Phasys phased array electronics has been incorporated, enabling the entire system to be operated by our own in-house software package.
The scanner now scans complex, dual curvature composite parts in pulse echo mode in a fraction of the time previously required. For example one component which previously took 95 minutes to scan on a conventional single probe USL squirter system is now scanned in 12 minutes using the phased array unit.
A video of the system can be seen at http://www.youtube.com/watch?v=TP1ooGh3QfM.
The dual robot system at USL has been relocated and configured for inspection of roto-symmetrical parts by the through transmission squirter method - see the picture. It has now successfuly completed inspection of a large composite part for an aerospace customer and will be available for future inspections of this and similar parts. Typically the linear scanning speed reaches 700mms/second with simultaneous control of all 12 robot axes - 2 robots, 6 axes each. The motion controller has been specially developed by USL to provide the position feedback rate necessary for scanning at high speed whilst maintaining accurate alignment between the water jets on each robot.