Inspection of Automatic Gear Boxes

Automatic gear boxes are characterised by a complex geometry due to variations of wall thickness, curved surfaces and specific constructional features in order to minimize the weight. So high requirements are put on the non-destructive test methods used for the inspections, which have to be integrated directly into the production line. Main focus is on the reliable detection of surface defects (initial cracks) and near-surface defects (pores). The integrated robot based system applies sophisticated imaging techniques for the fully automated signal processing. This allows a high efficiency of the inspections to be performed on all high-load sections (cycle time ~ 25 s per test part). Das komplett in die Fertigungslinie integrierte robotergestützte System nutzt bildgebende Verfahren zur vollautomatischen Signalauswertung und ist in der Lage, Zykluszeiten von max. 25 s / Teil zu ermöglichen.

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  • material: Aluminium die casting
  • different dimensions
  • varying wall thickness (0.85 – 5.0 mm)
  • complex geometry, openings and holes (for the purpose of weight reduction)
  • sensitive eddy current probes (customized), carried by a robotic system (KUKA)
  • detection of small pores (down to 0.4 mm in size)
  • crack detection on complex surface structures and edges
  • mechanics installation for 2 different parts (2 rotational units, placed side by side)
  • high test speeds (3000 rpm)
  • C-Scan comprising 7 test zones and the reference flaw (calibration)
  • enhancement of the ScanAlyzer software concerning specific algorithms for image processing and classification of pores (size and statistical distribution)

System Data

  • light metal frame with 2 rotational units for holding and rotating the test parts
  • multi-axis robot (KUKA), mounted on the frame
  • control cabinet containing eddy current Instrument (Elotest PL-500), Windows-PC (incl. ScanAlyzer software) and power electronics
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