Automation can be effectively integrated into various stages of penetrant line testing to enhance efficiency, consistency, and throughput.
1. Automated Material Handling and Positioning
Loading and unloading, moving parts between stations, raising and lowering shelves and baskets into immersion tanks and rotators and turntables can all be automated or part-automated for better accuracy and to reduce manual labour during testing.
2. Automated Processing Stations:
- Pre-Cleaning: Automated spray systems or immersion tanks with controlled agitation and temperature can ensure consistent cleaning. Automation can also be applied to Ultrasonic cleaning.
- Penetrant Application: Spray booths, robotic arms and dip tanks can all be controlled through automation for more even coverage of the penetrant, platform immersion time and drainage, ensuring efficient usage of materials.
- Excess Penetrant Removal:
- Automated Wash Stations and Emulsifier Application: Controlled water spray systems with adjustable pressure, temperature, and nozzle angles can ensure consistent removal of excess penetrant. Applying emulsifiers through automated spray systems ensures an even application.
3. Automation for Inspection:
- Automated Visual Inspection: Robotic systems equipped with cameras and image processing software can perform the visual inspection stage. These systems can be programmed to:
- Locate and identify indications based on size, shape, and intensity.
- Compare indications against predefined acceptance criteria.
- Generate automated pass/fail verdicts.
- Create inspection reports with images and data.
- UV Light Control: Automated systems can control UV light intensity and ambient light levels in inspection booths to ensure optimal viewing conditions for fluorescent penetrant testing.
- Coordinate Measuring Machines (CMMs): Integrated CMMs can automatically measure the dimensions and locations of any detected defects.
4. Process Control and Data Collection:
- Programmable Logic Controllers (PLCs): PLCs can control and synchronise the operation of the entire penetrant line, ensuring consistent processing times and sequences.
- Sensors and Feedback Systems: Sensors can monitor critical parameters like temperature, pressure, and chemical concentrations, providing feedback to the control system for adjustments.
- Data Logging and Traceability: Automated systems can record process parameters, inspection results, and part identification data for quality control and traceability purposes.
Benefits of Automation in Penetrant Line Testing
With increased throughput, improved consistency and enhanced accuracy, automation can play a pivotal role in Penetrant Line Testing when applied by qualified experts. Get in touch with ATH NDT for more information.