ROBOTIZED STATION FOR ANALYZING THE PRODUCT QUALITY WITH ULTRASOUND

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Product:

Ceramic fittings with different dimensions, weights, and various wall inclination angles. The measurements involve formed, fired, and not fired fire -resistant materials. The option of analyzing any number of fitting types – 57 product types were analyzed when the station was launched.

Purpose of the investment project:

The objective of the investment project was to improve the product quality by implementing an effective controlling procedure consisting in measuring non-destructively the density of refractory products with ultrasound automatically, and recording and processing the results obtained in reports.

Robot station:

In the application, a system of two type LRMate 200iD industrial robots from FANUC Robotics has been used with the following characteristics:

  • number of axes: 6
  • wrist's maximum load: 7 kg
  • repeatability: ±0.02 mm
  • range: 717 mm

Work head:

The robots are equipped with specialized heads with adapters for attaching measuring equipment and auxiliary devices:

  • Force Sensors, which specify the direction of pressing the heads against the fittings
  • Pundit Lab + meters
  • laser range finder (coarse measurement before the heads move close to the fitting)
  • automation systems, which make it possible to apply measurement probes perpendicularly to the surface of the fittings

Software:

The software makes it possible to read out and record measurement results and to convert them into the distribution of the density according to the algorithms developed.

Key functions of the system:

  • the ability to enter input data such as:
    - the dimensions of the fitting being examined (based on those dimensions the system presents the parameters and settings of the measurement table)
    - the number and location of measurement points
    - the characteristics of the density as a function of the speed of the ultrasonic wave for the specified type of ceramic material
  • the processing of the data obtained during the measurement
  • recording the data processed
  • presenting the fittings' density information in the form consistent with the manufacturer's expectations

Additional information:

Measurement

The measurement consists in applying measurement transducers against the fittings linearly, along the specified surfaces of the product. The instrumentation specifies the speed of the ultrasound passing through the material.

Remote servicing

Remote service access (e.g. to diagnose the device) is possible after the controller is directly connected to the Internet.