High Speed X-ray Solution For Process Control

Transcription

1 High Speed X-ray Solution For Process Control Hemanthkumar National Sales Manager for Industrial X ray solutions Nov

2 Agenda ZEISS Introduction. High Speed X-ray Solution CT High Speed X-ray solution IR Summary 2

3 Agenda ZEISS Introduction. High Speed X-ray Solution CT High Speed X-ray solution IR Summary 3

4 MARKENPRODUKTE BRANCHEN QUALITÄT SERVICE Mit unserer Leidenschaft für Spitzenleistungen schaffen wir Kundennutzen und inspirieren die Welt, Dinge neu zu sehen. Unsere Mission ZEISS is a leading group of companies in the optical and optoelectronic industries. Carl Zeiss AG is not publicly listed and is wholly owned by the Carl Zeiss Foundation. 4

5 Introduction to the ZEISS Group Key figures 2016/ billion euros revenue 770 million euros earnings (EBIT) >25000 employees (worldwide) As of 30 September

6 Introduction to the ZEISS Group Key figures 2016/ ~10% 10% patent applications of revenue for research & development of employees (worldwide) in research & development As of 30 September

7 Represented Worldwide Around 25 research and development sites Around 30 production sites Headquarters Oberkochen (southwest Germany) Just under 25,000 employees Over 50 sales and service sites Represented in over 40 countries 7

8 Agenda ZEISS Introduction. High Speed X-ray Solution CT High Speed X-ray solution IR Summary 8

9 CT system VoluMax VoluMax - High speed scans within few seconds or minutes - CT components optimally selected for certain application - Possible also fully automated evaluation based on specifications from customer - Possible evaluation independent on operator - Possibilities of automated loading / unloading parts - High power X-ray tube and high-speed detector - Very steady operation even in production area 9 9

10 Light alloy castings inspection Focus to aluminum parts casted with low pressures By sand casting, gravity die casting or low pressure die casting of light alloys appear usually specific problems, which are not common by high pressure die casting. Many times they are related to stability of used cores (from sand or salt), lower accuracy, lower speed of casting, thicker walls etc. 10

11 Light alloy castings inspection Classification of problems and advantage of CT technology by their identification With CT technology we are able to recognize and quantify many different problems in castings like e.g. cold shots, blisters, gas pores, shrinkage holes, sand residual, inclusions, thermal fatigues, flashes, broken cores, etc. 1 11

12 Standard methods of inspection visual method with bore-scopes and nondestructive X-ray radiography limitations of these methods Voids in casting after machining Sand in channels Flashes Radiographic methods are fast and non destructive. By using of reference images is stability of inspection enhanced, but in comparison to CT technology the accuracy of results (size and location of defects in 3D volume) is still very poor. Visual inspections like e.g. endoscopic inspection with bore scopes is slow and manual process with very subjective and inaccurate results due to deformed pictures. Destructive methods like metallography are also often used, but this method leads to irreversible cutting parts and are really time expensive and effortful. 1 12

13 InLine installation possible Layout Parts are delivered to the inspection area with the conveyor. Robotic arm takes parts from input conveyor (blue arrow) and loads them to VoluMax. Parts are scanned within 1 1,5 minute and evaluation starts afterwards. Parts are waiting for results in the depot during the scan of next part. After the evaluation go parts depending on result to one of the output conveyors. Good parts go further to machining station (green arrow) and NOK parts to the waste (red arrow). 1 13

14 Cylinder heads Options for detection of imperfections Sand core related defects Typical problem of low pressure casting methods are related to sand form or sand cores. If the core is broken or moved to the side, part might be dysfunctional. Therefore e.g. detection of complexity of water jacket is one of the main tasks for such parts. Residua of sand, broken core or displacement of the core can be detected automatically. 1 14

15 Cylinder heads Options for detection of imperfections Other defects Voids like blisters, pores or shrinkage holes are often also very important, mostly when they are located close to the surface of the part or even when they go or will go through of machined surface. With CT system we can automatically sort parts according to their position in relation to the machined surfaces. 1 15

16 Automatic defect detection on machined surfaces prediction of problems during the production process Scanned raw part (only casted) Registration of these two datasets, based on alignment in production (same alignment method as used for milling of raw part) CAD model of final product (after machining) 1 16

17 Automatic defect detection on machined surfaces improving production process by prediction classifying defects based on information from CAD model The biggest voids connected to the surface of CAD model shows, that part after machining will be classified as nok. It is not necessary to machine this part anymore. This prediction shows the problems which will appear only after machining. The prediction of potential defects leads to a reduction of production costs and decreasing production time. Regions of interest are only areas around machine surfaces. They are marked in semi transparent blue

18 Reporting the results visualization of detected defects color map describes probability of the defects and their size 18 1

19 Computed Tomography ZEISS VoluMax High Speed CT Transparency of your part in seconds Additionally to the good bad part evaluation more valuable information can be gathered in the production. Pore analysis // Surface prediction // Result of tool wear Trend Analyses Defect size Defect location Number of defects Dimensional variation Shape variation Prognoses of mold live time Process feedback. Live monitoring of the process is the opportunity to avoid waste! 19

20 ZEISS VoluMax Platforms and customized automation options Platform type VoluMax 400 VoluMax 800 VoluMax 1500 Source/detector distance 400 mm 800 mm 1,500 mm Scan volume dia. 160 x 95 mm dia. 170 x 150 (405) mm dia. 305 x 260 (655) mm Scan volume with detector extension dia. 260 x 325 mm dia. 300 x 390 mm dia. 570 x 550 mm Tube types, alternatives 39 W 39 W 1,600 W 1,800 W 1,600 W 1,800 W Detector resolutions,, alternatives 1920 x 1536 Px 1920 x 1536 Px 1024 x 1024 Px 512 x 512 Px 1024 x 1024 Px Tube Types Power Type Voltage Focal spot 39 W Closed tube 130 kv 5/8/20/40 μm 1,600 W Closed tube 225 kv 250/300/500/800 μm 1,800 W Closed tube 225 kv 400/1,000 μm 20

21 CT systems for process-parallel inspection description of offered systems VoluMax kv VF or DF vario focus (dual focus) 225 kv 1600 W (1800 W) X ray tube Detector with resolution 1024 x 1024 Px Suitable for at Line and in line installation Universal system for high speed scans with times even under one minute VoluMax kv VF of DF vario focus (dual focus) 225 kv 1600 W (1800 W) X ray tube Detector with resolution 1024 x 1024 Px and 4 times bigger area For parts with size up to circa ø 440 x 650 mm Suitable for at Line and in line installation Universal system for high speed scans with times even under one minute 21 2

22 Agenda ZEISS Introduction. High Speed X-ray Solution CT High Speed X-ray solution IR Summary 22

23 Aluminum Alloy wheel IR system 23

24 Multi-Purpose IR System 24

25 Piston Inspection IR System 25

26 Agenda ZEISS Introduction. High Speed X-ray Solution CT High Speed X-ray solution IR Summary 26

27 High Speed X-ray Solution For Process Control 100% inspection of Aluminum cast parts are possible in IR & CT systems. Complete analysis is done in non destructive way and hence no wastage of parts. Only good parts are processed for the next sequence of operation. Metrology, CAD comparison, Porosity Analysis, Wall thickness are possible.. Statistical Analysis of all essential parameters of scans & will be available for evaluation and cross verification at any given point of time. Availability of Digital data for your customer discussions. You are always sure that you delivered the Right part to your customer Saves time and money... 27

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