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PHAsisBLU spot weld inspection system with robots

Spot weld inspection system with imaging phased array technology for automated, robotic non destructive testing of spot welds and longitudinally welded short seams.
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Automated with robots

PHAsisBLU Spot weld inspection system

PHAsis®BLU was specially developed for time-saving robot-supported inspection of spot welds and short seams made of steel and aluminum.
It is ideal for testing 2- and 3-sheet joints with a single sheet thickness of 0.6 mm to 5 mm. The use of robot technology enables not only the reduction of the testing time but also the improvement of the reproducibility of the measurements. Cycle times of 5-10 seconds per spot weld are achieved.

PHAsisBLU-Neue-Version
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  • Automated testing

    Fast and precise robot-supported inspection

  • Precise

    729 virtual probes and a physical resolution more precise than 0.35 mm

  • Minimal coupling agent requirement

    when using water. Surface dries independently within a few minutes

  • > 25 years of experience

    in spot weld­testing joined in PHAsis

Outstanding Features

  • Imaging display of the spot weld as a live scan (C-scan) and as a result (D-scan, depth-accurate)

  • Fast processing and evaluation of test data by use of multicore technology

  • Rugged, milled, solid housing

  • Simple mounting of the inspection device

  • Service-friendly component exchange

  • Fast and economical repairs due to good accessibility of the components

  • Windows operating system 64 bit

  • Customer‘s own computer systems can be used, resulting in high serviceability

  • Remote access via WLAN for setting and service action

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Advantages of PHAsisBLU Phased Array Ultrasound Technology

  • Imaging display of the spot weld as a live scan (C-scan) and as a result (D-scan, depth-accurate)

  • Fast processing and evaluation of test data by use of multicore technology

  • Rugged, milled, solid housing

  • Simple mounting of the inspection device

  • Service-friendly component exchange

  • Fast and economical repairs due to good accessibility of the components

  • Windows operating system 64 bit

  • Customer‘s own computer systems can be used, resulting in high serviceability

  • Remote access via WLAN for setting and service action

VOGT Ultrasonics Your reliable partner

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The test sequence with robot

The PHAsis® inspection and evaluation software communicates the inspection plan with the robot controller via a standardized REST interface. Spot welds defined in the inspection plan are individually approached and inspected with the parameter sets defined for the spot.

A typical test island set up for 24/7 operation often looks like this:

Variant 1: The robot scans the part number and feeds the part to the fixed inspection unit.

Variant 2: Alternatively, a robot guides the inspection probe in the same way as the materials tester does by hand and moves it from weld spot to weld spot on a positioned component. In this case, the inspection probe is mounted on the robot arm together with the coupling agent inspection unit and the camera.

By coupling via a water supply line with a flexible plastic membrane, the inspection head can be precisely aligned with the weld spot, which is important in the case of displaced weld spots. A big advantage is the minimal wetting for coupling, which is sufficient when using the VOGT membrane. When using water, the advantage is that the sprayed water evaporates quickly. This eliminates the need to remove the coupling agent, which is also required by Rexolite solid-state leader sections commonly used this day.

The robot follows an inspection plan, so individual spot weld dependent setup and evaluation parameters are also automatically invoked. Inspection results are synchronized with host systems or/and the PHAsis database. In addition, the system offers a data manager as well as a post-processor for subsequent optimizations or special evaluations.

Delivery scope for the connection to the robot technology

We supply the following tools for use with robots:

  • Communication interface: Automation interface, PHReAP (REST interface), interface license / interface license for device remote control, per PHAsis ultrasonic device, including detailed description

  • Probe mounting incl. coupling nozzle for PHAsis probe diameter of 24 mm for mounting on a robot

  • Reference plate with reflectors for system monitoring and calibration

  • Export interface for test results, import interface for test plans

  • 4 distance information for vertical alignment on the spot weld surface via automation interface

PHAsisBLU can also be used mobile & manual

You can also use PHAsisBLU as a mobile inspection system solution for manual ultrasonic testing.

With our test trolley, you can transform PHAsisBLU into a complete, mobile workstation. It enables long-term operation without mains power with exchangeable high-performance battery units.

Fig.: PHAsis®BLU with inspection trolley

 

PHAsis your reliable testing system

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PHAsis in action:

Video: Inspection mode “Inspection acc. to test plan” 
Video: Die PHAsisMANAGER administration software
Video: PHAsis delay lines
Video: Inspection mode “Free Testing”
Video: Assembly of the water delay line
Video: Inspection of spot welded joints of titanium
Video: PHAsis delay lines
Video: Inspection of spot welded joints of titanium