OKOndt Group at 20th World Conference on Non-Destructive Testing (20th WCNDT), Incheon, Korea May 2024.

Automated testing

OKOndt GROUP™ provides users with a large amount of ultrasonic testing machines outfitted for the purposes of automated non-destructive testing.


Mechanized ndt systems are used for solving testing tasks in variety of situations, in which usage of portable flaw detectors is either problematic or impossible, for example, complex testing of railcar wheelsets. Non-destructive testing systems are usually based around three automated ndt methods: ultrasonic, magnetic and eddy-current. Automatic ultrasonic testing is mainly used to solve tasks of large-scale inspection such as longitudinal pipes or railway axles. Conventional ultrasonic testing system developed by OKOndt GROUP™ is capable of not only testing, but also of collecting and providing information acquired during the on-site test, for post-processing. Magnetic methods are also applied in ndt systems produced by OKOndt GROUP™. These methods are either used alone or in combination with other non-destructive testing techniques, in order to acquire valid information about the condition of tested object. Non-destructive testing system based solely on magnetic ndt method provides users with highly accurate information about the test object surface condition. Eddy-current systems are used for testing parts with complicated shape, and critical structural elements, or as a supplementary tool for other methods. Eddy-current technique is common in avionics, as well as rail wheels and longitudinal tubes inspection. To obtain comprehensive and accurate information about test objects, the above methods can be combined in an integrated inspection system. Thus, ultrasonic systems paired with magnetic subsystems are widely used for testing rail wheels. Usage of different non-destructive methods in the same ndt system allows to avoid drawbacks and to further improve benefits of the combined techniques. Non-destructive testing machine manufactured by OKOndt GROUP™ is highly reliable and precise equipment, capable of conducting complex tests of multiple objects. Data acquired by ultrasonic, magnetic or eddy-current non-destructive testing system can also be used for post-processing, thus allowing the user to further increase the test accuracy. Bellow you can see some our examples of our non-destructive testing systems for different purposes.



Magnetic Particle and Ultrasonic Inspection System


Automated line for magnetic particle and ultrasonic testing of railway wheel rim, hub, disk and flange to be integrated into the wheel inspection station.

The line includes:

  • Magnetic particle inspection equipment for in-production testing of railway wheels for the presence of surface defects by fluorescent-magnetic technique in accordance with EN 13262, ISO 6933, ААR M107, DIN EN ISO-9934-1,2,3, GOST 10791.
  • Ultrasonic testing system ensures inspection of wheels according to EN 13262 & AAR M 107/208, GOST 10791, followed by return of tested wheels to the finished product acceptance facility.

The line solves the following tasks:

  • conformity to quality control requirements for wheel products as per GOST 10791-2011, with test productivity of 25 wheels/hour;
  • conformity to quality control requirements for machined wheel centers having a flange, as per TUU 35.2-23365425-640:2009 &TU U 35.2-23365425-643:2009, with test productivity of 20 wheel centers/hour;
  • compliance with quality control requirements for machined locomotive wheels with outer diameter of the rolling circle up to 1350 mm, with test productivity of 10 - 20 wheels/hour, depending on the product size range and specific standard requirements;
  • compliance with quality control requirements for machined freight car wheels of American railways with Ø28"÷ 43" and test productivity of 20 - 25 wheels/hour;
  • test result data communication to a single server of the inspection station, followed by generation of test reports.



SMARTSCAN Aircraft Wheel Inspection System


Purpose

SMARTSCAN Aircraft Wheel Inspection System is intended for testing of main and nose wheels of aircrafts of various world manufacturers such as Messier - Bugatti, Goodrich, Honeywell, Maggitt and others.

Meets the requirement ISO 15548-1

The System ensures the testing of the following wheel areas:

  • tubewell;
  • bead seat;
  • flange.

Parameters of the testing object

Outer diameters of the tested wheels:

  • minimum - 190 mm;
  • maximum - 900 mm.

Diameters of the centered holes of the tested wheels:

  • minimum - from 40 mm;
  • maximum - up to 200 mm.

The System operation features

The System is controlled both from the operator's panel, and from the interface of the special-purpose software.

The main operating modes of the SMARTSCAN system are "Manual" and "Automatic".

In the "Manual" mode of operation, the System provides multiple movement of the eddy current probe (ECP) along the defect on the reference block allowing the operator to carry out rapid adjustment of the eddy current flaw detector.

Also, in the "Manual" operating mode, the operator is able to determine the coordinates for setting up the system for the wheel type to be tested:

  • wheel lift assembly for lifting the wheels above the surface of the transportation rollers,
  • the mechanism for moving the ECP to determine the coordinate of the ECP approach point at the beginning of the testing, as well as the coordinate of ECP take-off point, upon completion of the testing.

In the «Automatic» mode of operation, the System ensures the scanning of the reference block in order to check the feasibility of ECP operation before starting the testing process, ensures an automatic scanning of the aircraft wheel surface, as well as conducts the scanning of the reference block to check the feasibility of ECP operation after the testing is finished.

The System is equipped with the remote "Pause" button, which allows the operator to stop testing, perform the confirmatory testing procedure, or sorting the area where the threshold was exceeded by the ECP signals.

The mechanism for capturing the wheel hub allows the aircraft wheels to be centered, at the testing positions, weighing up to 150 kg and perform their rotation with a speed of up to 120 rpm.

The System provides the testing of wheels both with down and up flange position allowing to test the wheel halves without the hub, in case of using the face-plate.

To prevent personnel injury, as well as the damage of the ECP, the System is equipped with hardware locks which, if the permissible force is exceeded, block the movement mechanism of the ECP.



Automated ultrasonic and eddy current system for mill rolls testing SNK B-35 (L)


Purpose

SNK B-35 (L) is designed to automatically detect inadmissible internal and external defects of the roll body (breaking of the continuity of the metal such as: reed mark, flux inclusion, crack, fold, cleavage, etc.) with the issuance of protocols on the usability


Features

  • SNK B-35 (L) is integrated to the support of the roll-grinding machine, regardless of the type and manufacturer;
  • Online display of the position of the scanner in the real coordinate system of the grinding machine;

Calibration mode

  • Automatic splitting of the roll into testing zones;
  • Automatic generation of AVG-diagrams for each zone, taking into account the attenuation rate;
  • Determining the level of the bottom echo signal drop below the fixation level for each zone;
  • Viewing the results of testing in the 3D dimensional display of the mill roll with the spatial location of the defects.

Benefits

  • The testing is performed as a technological stage after machining, grinding both newly manufactured and repaired mill rolls directly at the machining station, without trans-shipment;
  • Extension of life service of repaired mill rolls according to inspection results;
  • Availability of remote on-line technical assistance service, and technical support programs.



Wet fluorescent magnetic particle testing of railway axles


UMPKOS-38 system is designed for magnetic particle inspection of railcar wheels axles during production and after repair.

The system is able to detect both longitudinal and transverse surface flaws (‘B’ sensitivity level as per GOST 21105) in accordance with EN 13261, GOST 31334, RD 32.144-2000, by wet fluorescent magnetic particle technique, using AC combined magnetizing (circular, polar). The system provides 100% inspection of the entire axle surface, except for ends.

This stationary-type system can be either integrated into the workshop process line or operated independently as a stand-alone MT station. Magnetic fluid is made of finely-cleaned degassed water, free from mechanical impurities and fat inclusions.

Test object specifications:

Axles with the below parameters are subject to testing by the system:

  • maximum diameter – 390 mm;
  • minimum diameter of axle journal – 100 mm;
  • maximum length – 2500 mm;
  • minimum length – 1500 mm;
  • temperature of test object: +3 °С to +45 °С.

Please, read the customer feedback here...




SNK KP-8 automated system for integrated nondestructive testing of railcar wheelsets


Purpose

  • The System is intended for detection of both surface and inside flaws in freight railcar wheelsets, as well as for measurement of flaw depth and coordinates;
  • Automated inspection is performed on the wheel sets with new machined wheels and repaired axle.

Features

  • The System is used for automated UT, EMAT and ET of railcar wheelsets at repair plants that assemble and examine the newly formed wheelsets;
  • Inspections of the freight railcar wheelsets performed by the System are aimed at confirmatory testing or detection of the existing flaws of in-service or repair origin in the wheelset axle, wheel disk, remand flange, as well as at determining the flaw locations;
  • The System carries out ultrasonic and eddy current inspection of used wheelset components to be further examined or repaired;
  • Testing productivity is no less than ten (10) wheelsets/hour provided that they are smoothly fed to the test position.

Benefits

The use of automated wheelset inspection System allows increasing the testing productivity and reliability by several times due to simultaneous operation of multiple channels. Not only detected flaws but also all process data are fully recorded by the System during inspections. This helps to avoid NDT inspector’s mistake or negligence, and enables to make a detailed analysis of test results at any time.




AUTS Axle-4 OS-4 system for automated ultrasonic inspection of railway axles during production


Purpose

  • Main purpose of the system is to find all kinds of defects in railway axle body according to RD32.144-2000, EN 13261, М101, DSTU 31334 & BN 918275;
  • The system is able to examine machined or semi-machined axles during their production.

Features

  • Ultrasonic testing is automatically performed from the radial surface by immersion technique;
  • Axle to be tested is fully placed into the immersion tank, where it is rotated by central clamping devices, and scanning is performed during linear motion of UT scanner along the axle;
  • The system estimates equivalent sizes and depths of the defects;
  • Axle is inspected along its entire length, except for dead zones in center and bolt holes;
  • Testing facility has its own closed-circuit system of immersion liquid intake, supply and purification.

Benefits

  • Design of the system is compact and ergonomic;
  • The system can be either integrated into the production line or operated as a stand-alone inspection station;
  • Metal structure test is also provided to check the structure conformity to applicable standards;
  • High productivity of the system is due to absence of multiplexing schemes in eight scanning modules. Time required for inspection of one axle is up to 8 min.

Please, read the customer feedback here...




PSh-11 ERW system for nondestructive testing of pipes


Purpose

  • The system performs a comprehensive automated ultrasonic inspection of welds in longitudinally welded small-diameter pipes during their production;
  • Inner and outer longitudinal defects, as well as residual inside and outside flash are subject to detection in accordance with API Spec 5CT, GOST R 52203-2004, TU 14-3R-27-2000, TU 14-3R-28-2001, TU 14-3R-29-2002, TU 14-3R-31-2005.

Features

  • The system is to be installed immediately downstream the ERW mill and flash trimmer before the local weld zone heat treatment station;
  • It comprises a fusion- and near-weld zone flaw detection module, as well as pipe profile measurement module in heat-affected area;
  • Pipes are supplied to the inspection station at a linear speed up to 1 m/s.

Benefits

  • Heavy-duty equipment capable of operating in harsh industrial environment, such as high temperatures up to 250 °С in test area, and ample scaling;
  • Availability of flaw marker for defective pipe sections, and sending of ‘Reject’ alarms to the production line;
  • Fully automated inspection process, practically unattended by operator.



System of automated ultrasonic quality testing of the wheels and rims «SNK KB –13»


The System is intended for work in assembly with the line of control of wheel and rim products.

The «SNK KB – 13»  System assures the testing of the wheels and rims in compliance with AAR M 107/208 and EN 13262, UIC 810-1, ISO 5948, with the subsequent return of the tested products to the finished products acceptance Stand.

Finished and machined railway wheels and rims with the following parameters are subject to test using the «SNK KB – 13» System:

  • wheel/rim weight — from 200 kg to 1300 kg;
  • wheel/rim diameter — from 700 kg to 1350 kg;
  • rim width — from 80 mm to 160 mm;
  • rim thickness — from 35 mm to 150 mm.

The «SNK KB – 13» System allows performing ultrasonic testing of the tread of car wheel/wheel in axial and radial directions, of the wheel hub - in two opposite directions by the ultrasonic method, with imaging of the test process, the test results verification for compliance with the standard, and test results data transfer to the server with the subsequent documentation of test results.

The «SNK KB – 13» System provides the following functions:

  • testing of the tread of a car wheel in axial and radial direction. Minimal defect diameter – 1 mm. Minimal depth of the defect – 5 mm.
  • wheel hub testing in axial direction. Minimal defect diameter – 3 mm. Minimal depth of the defect – 5 mm.
  • Possibility to configure the test that allows to limit the defects quantity and the distance between the defects in compliance with the standards.
  • evaluation of the defects parameters (defect depth, approximate coordinate, amplitude, equivalent defect size, equivalent area in millimeters).
  • defects parameters display in the “Defects Table/Defectogram”, in the A-Scan, B-Scan, and C-Scan, saving the data to the System memory, with a possibility to print them out.
  • Light and sound Defect Alarm.
  • Saving of various test configurations with different probe sets, coordinates, travel speeds.
  • Good products and defects marking with paint in order to confirm the defect further in manual mode.
  • Test results (protocols) output in electronic version in «.xls» or «.pdf» formats with a possibility to print them out on paper.

The «SNK KB – 13» System is operated by the dedicated software which enables automatic management of the System mechanical units, as well as the test results reading, processing, and recording.

System design ensures the safety of maintenance personnel, automatic blocking, alarm, and emergency shutdown.

Main parameters and features

  • The «SNK KB – 13» System test throughput – from 10 wheels/rims per hour.
  • The «SNK KB – 13»  System readjustment time and preparation for another wheel/rim type scanning at given software configuration for a specific assortment is not more than 10 min; for another assortment when the software is not configured – not more than 120 min.
  • Generator sounding pulse amplitude is not less than 180 V at the pulse duration (60 ± 20) ns and the duration of the leading edge is not more than 20 ns.
  • Operating frequency of the probe – 4-5 MHz
  • Number of ultrasonic channels – 6.
  • Maximum PRF – 2000 Hz.
  • Channel sensitivity (Signal to noise ratio) – 16 dB.
  • Involute measurement step – can be adjusted within 1 to 8 mm.
  • Absolute error of the defect depth – not more than ±3 mm.
  • Absolute error of the defects relative position along the scanning path – not more ± 15 mm.