Genesis Automated and Robotic Phased Array Ultrasonic Testing

Accurate, Flexible Ultrasonic Non-Destructive Inspection for Materials and Parts

Ideal for inspecting welds or detecting flaws in solid materials, Phased Array Ultrasonic Testing (PAUT) generates ultrasonic signals by pulsing groups of ultrasonic emitters at intervals to provide cross-section views of materials. The PAUT inspection device emits multiple ultrasonic pulses from differing angles, creating an electronic image of a material’s cross-section that can be examined for defects.

Genesis PAUT inspection applications include:

  • Aerospace inspection
  • Weld inspection
  • Large and small part sizes
  • Scanning components with complex geometries
Phased Array Ultrasonic Testing
Phased Array Ultrasonic Testing
Phased Array Ultrasonic Testing
Phased Array Ultrasonic Testing
Phased Array Ultrasonic Testing
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View Video Transcript
Genesis’s NSpect RoboPogo NDI system delivers phased array ultrasonic capabilities for the non-destructive testing of composite parts of complex geometry in a “process-to-part” operation.

This RoboPogo robotic tooling system includes nineteen KUKA robots, each with a pneumatic End of Arm Tool to firmly yet carefully hold lengthy parts to be inspected. The system includes a track mounted NDI robot that traverses along a linear servo track, delivering a Phased Array process to the part via designated robot end of arm tools.

During the scan process, the robot will pick up and drop off the necessary inspection end of arm tool as needed. All scans designated for that tool will be completed before dropping it off and retrieving the next end of arm tool. This will alleviate the need for the robot to pick up the same end of arm tool multiple times during the scan cycle, reducing the cycle time and increasing thru put.

Once the designated end of arm tool has been retrieved by the inspection robot, it will move to its predefined point to begin the scan. The water will be purged through the end of arm tool to ensure no air is present, and the robot will manipulate the sensor onto the part to achieve adequate coupling for inspection.

The NDI robot will then manipulate end of arm tools along the flat surfaces and radii of the part to be inspected. During the scan, pulse-on-position trigger signals will be passed to the ultrasonic inspection instrument and the data acquisition system such that the inspection results can be plotted in a C-Scan format for analysis. The included UTEX/Olympus NDI package will be responsible for tracking and mapping each scanned path with each end of arm tool.

One of the many advantages of this configuration is to allow the fixturing robots to move independently during the scan, allowing each robot arm to un-clamp the part and drop out of the way as the NDI robot passes the inspection sensor over that area of the part to provide clearance without any obstruction. Once the sensor has completed the scan in that area, the fixture robot will resume its position and re-clamp the part. This functionality is achieved by assigning thresholds for the relative positions of the robots, and the motion of these robots are programmed via the primary system HMI.

The Genesis’s NSpect RoboPogo NDI system includes a wireless control pendant, water reclamation and conditioning package.

Simplifying maintenance is at the forefront of the system and includes the end of arm tool maintenance cart. The Kuka track mounted robot delivers the required end of arm tool needing service to the maintenance cart. The operator then easily transports the end of arm tool to the maintenance department.

Genesis systems experience in the aerospace and aircraft sectors delivers unparalleled inspection and testing capabilities for enhanced productivity increased accuracy and accelerated thru put. Genesis’s NSpect RoboPogo NDI system builds on that experience delivering a positive return on investment
Please Contact Genesis Systems for more information.

View Video Transcript
The Genesis Mobile Robotic Inspection system provides an automated ultrasonic inspection of friction stir welds, and other NDI processes. The system is custom designed for aerospace and aircraft NDI professionals and manufacturing engineers who need to balance high quality and speed for non-destructive inspection (of large objects)?

The self-powered mobile platform consists of a heavy‐duty steel main structure and a KUKA robot package. The system’s control panel, as well as the operator station is integrated into the platform.

The Mobile inspection system includes Ultrasonic Process Equipment packages that include Olympus instruments, Inspection-Ware and phased arrays/shoes

Changing among ultrasonic sensors is easily achieved with the tool changer concept. The robot can be directed to present the End of Arm Tool at an ergonomic position for the Operator, and array tools can be released with the push of a button.

This system is designed to processes parts in a “process‐to‐part” operation.
The robot will manipulate an End of Arm Tool along the surfaces of the welds to be inspected. During the scan, pulse‐on‐position trigger signals will be passed to the ultrasonic inspection instrument and the data acquisition system such that the inspection results can be plotted in a C‐Scan format for analysis. Although intended for multi-array sensor inspections of friction stir welds, the equipment can also be applied to most single-sided (pulse echo) ultrasonic inspection processes – including carbon fiber structures.

The motor driven platform will enable the operator to manually drive the mobile system via handheld pendant, without the need for any external equipment. The mobility portion of this platform will be fully battery operated, eliminating the need for any power cords to be attached while maneuvering the system throughout the facility.

Genesis has successfully developed a full line of robotic work cells for non-destructive inspection that consistently meet the ever-increasing demands of the aerospace and aircraft industries

View Video Transcript
Genesis’s NSpect Kompackt workcell NDI system delivers non-destructive Inspection of composite parts in a “process-to-part” operation.
This small footprint system features a single, track-mounted robot with 6 degrees of motion which manipulates a 128 element linear array along a part surface. The ultrasonic process is powered by an integrated Olympus Focus PX phased array instrument. A three screen HMI enables the operator to utilize Inspectionware Acquistion and analysis software and Vector programming.
During the scan, pulse-on-position trigger signals will be passed to the ultrasonic inspection instrument and data acquisition PC such that the inspection results can be plotted in a C-Scan format for analysis
Robot positional data is communicated as fast as 4 kHz by the Genesis Blitz module. The collected data is then combined with ultrasonic waveforms using UTEX InspectionWare software, which also features sophisticated data analysis capabilities.
The NSpect Kompackt workcell system is designed to inspect both flat and contoured parts in and/or above the immersion tank.
With experience in the Aviation, Space and Defense markets, Genesis Systems delivers unparalleled inspection and testing capabilities for enhanced productivity, increased accuracy and accelerated throughput. Genesis’s NSpect Kompackt NDI system builds on that experience delivering a positive return on investment
Contact Genesis Systems for more information.

Want to learn more about how PAUT technology can improve your inspection process? Visit our world-class Automation Solutions Center where you can meet our experts and test our systems before making a purchase.

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