NDT-PT1200 Customized Manual Roller Type Fluorescent Penetrant Testing Line for Non-Magnetic Parts FPI Testing
1. Equipment Usage:
This production line is mainly used for fluorescent penetrant inspection of non-magnetic parts, detecting discontinuous defects in the non-porous surfaces of the parts.
1.1 Part Specifications:
Diameter: φ500mm
Length: 450mm
Weight: 50 - 60kg
1.2 Applicable Standards: ASTM E1417, ASTM E165, ISO 3452, ISO 3059
Main Technical Parameters
5.1 Permeation tanks (2 sets)
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Serial Number
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Technical Requirements
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Accessory Requirements
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1
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Internal dimensions: 1200 × 800 × 800 mm (depth)
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AlSl304 - 2.5 mm fabrication
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2
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This tank consists of a penetration tank and a drip tray. It is equipped with an electric lifting device for the parts. The drip tray can directly return the dripped penetrant fluid back to the penetration tank; the width of the drip tray is 600mm.
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The side of the bracket that comes into contact with the parts has a non-metallic material protective layer to prevent scratches and collisions.
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3
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The bottom of the infiltration tank is designed with a liquid discharge outlet.
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4
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The independent control panel in front of the tank can display the temperature of the liquid inside the tank, set and adjust the time for penetration and dripping respectively, and has an alarm device.
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PLC control. The penetration and dripping time can be set separately. It is equipped with an audible and visual alarm system. The time is displayed digitally. A temperature sensor is installed at the lower end.
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5
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The temperature sensor is installed at the appropriate position, which can accurately display the temperature. Once the set temperature is reached, it will automatically cut off the power supply.
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6
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Equipped with a water gun for rinsing, used for manually flushing out the penetrating liquid.
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5.2 Emulsification drip chute (1 set)
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Serial Number
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Technical Requirements
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Accessory Requirements
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1
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Internal dimensions: 1200 × 800 × 800 mm (depth)
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AlSl304 - 2.5 mm fabrication
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2
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This trough consists of an emulsification tank and a drip chute, and is equipped with an electrically operated lifting device for the parts.
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The side of the bracket that comes into contact with the parts has a non-metallic material protective layer to prevent scratches and collisions.
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3
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The bottom of the emulsification tank is designed with a liquid discharge port.
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4
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The independent control panel in front of the tank can display the temperature of the emulsion inside the tank, and allows for setting and adjustment of the emulsification and dripping times separately. It also has an alarm device.
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PLC control. The emulsification and dripping time can be set separately. It is equipped with an audible and visual alarm system. The time is displayed digitally, and a temperature sensor is installed at the lower end.
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5
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The temperature sensor is installed at the appropriate position, which can accurately display the temperature. Once the set temperature is reached, it will automatically cut off the power supply.
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6
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Equipped with a water gun for rinsing, used for manually flushing out the penetrating liquid.
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5.3 Automatic cleaning tank (1 set)
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Serial Number
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Technical Requirements
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Accessory Requirements
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1
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Internal dimensions: 1200 × 800 × 800 mm (depth)
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AlSl304 - 2.5 mm fabrication
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2
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There is a grid frame inside the slot.
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3
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Pneumatic door opening and closing mechanism
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4
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The bottom of the trough is equipped with a drainage valve, along with an inlet and an overflow outlet.
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5
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The independent control panel in front of the tank allows for the separate setting and adjustment of the cleaning time and temperature inside the tank, and it is equipped with an alarm device.
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PLC control, equipped with an audible and visual alarm system, with digital time display, and a temperature sensor at the lower end.
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5.4 Manual cleaning tank (1 set)
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Serial Number
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Technical Requirements
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Accessory Requirements
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1
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Effective dimensions inside the slot: 1200 × 800 × 800 (mm) deep
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AlSl304 - 2.5 mm fabrication
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2
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The countertop is placed on a stainless steel grid (at 400mm), and the countertop is made of oil-resistant, detachable non-metallic thick plate material.
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The bottom of the trough is equipped with a drainage outlet.
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3
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A stainless steel movable darkroom is installed on the slot, and a waterproof ultraviolet lamp is installed in the darkroom. In front of the operator in the darkroom, there is a water-blocking plate with an air outlet. The white light is equipped with a ventilation device, and a shading curtain is also provided to remove the penetrating liquid water mist generated by manual cleaning in the darkroom.
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5
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In addition, the side of the tank is equipped with ultraviolet lamps, and there are one water spray gun and one air spray gun. The water washing pressure is no more than 0.27 Mpa, and the air spray gun pressure is no more than 0.17 Mpa.
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6
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The water temperature for cleaning should be between 15 and 40 degrees.
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7
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The pressure gauge can be placed on the operation panel, and the water pressure and water temperature operation is available on both the front and rear sides.
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5.5 Drying oven (1 set)
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Serial Number
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Technical Requirements
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Accessory Requirements
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1
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Slot dimensions: 1200 × 800 × 800 (mm) depth
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AlSl304 - 2.5 mm fabrication
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2
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The oven adopts a hot air circulation electric heating method (to overcome noise), and the temperature inside the box should be able to be continuously adjusted from room temperature to 80ºC. The temperature control accuracy is ±2℃, the temperature uniformity inside the box is ±5℃, and it can perform automatic temperature compensation.
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A temperature-resistant sealing gasket is used to seal between the slot and the slot cover, ensuring that the dry hot air does not leak out.
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3
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The slot is equipped with a grid frame for placing parts.
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4
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There is 50mm thick insulation cotton between the inner and outer walls.
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5
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The independent control panel can regulate the drying time and temperature, and it also has an alarm function.
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PLC control, capable of automatically cutting off the heating power supply
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6
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Equipped with a digital temperature control meter with PID regulation.
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5.6 Empty box (1 set)
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Serial Number
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Technical Requirements
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Accessory Requirements
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1
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Slot dimensions: 1200 × 800 × 800 (mm) depth
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AlSl304 - 2.5 mm fabrication
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2
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The slot is equipped with a grid frame for storing parts, with an open front and a material storage buffer area.
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5.7 Imaging slot (1 set)
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Serial Number
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Technical Requirements
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Accessory Requirements
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1
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Size: 1200 × 800 × 800 depth (mm)
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AlSl304 - 2.5 mm fabrication
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2
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The grille frame is installed inside the slot.
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3
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There is an independent powder container.
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4
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The powder spraying adopts automatic powder spraying (both top and bottom spraying). The outer wall of the powder tank is equipped with a heating device, which can ensure that the imaging powder is dry and loose. The negative pressure and sealing devices can guarantee that the powder spraying is uniform and the imaging powder does not leak out.
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5
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Configure the air blow gun, with the air pressure not exceeding 0.03 Mpa.
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6
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The pressure for the powder explosion and the air gun can be adjusted separately.
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Equipped with a pressure gauge
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7
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It is equipped with a ventilation interface to extract the excessive dust.
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8
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An independent control panel is installed in front of the slot, which can control the powder spraying time and has an alarm function.
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9
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The dust removal time can be controlled and adjusted.
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5.7. Electrical Control System
The system adopts a centralized control method, enabling control over the operation process of the workstations. The electrical control system mainly consists of a programmable sequential controller (PLC), various relays, AC contactors, automatic switches, temperature controllers, digital timers, etc. The time settings for each slot can be conveniently made and modified on the digital timers.
5.8. Conveying System
The conveying rollers are made of stainless steel bearing rollers, and they can achieve the purpose of conveying by simply pushing gently.
5.9. Pneumatic Control System
It mainly consists of an air source treatment triad, solenoid valves, pressure gauges, cylinders, and various pneumatic control and actuating elements. The water and air spray guns, negative pressure guns, and imaging devices are equipped with oil-water separators for their air supply, and the blowing powder guns and water and air spray guns use small-range pressure gauges for easy data reading. Pressure gauges and pressure regulating devices are installed at all locations that use water and compressed air.
2. Equipment Overview:
The fluorescent penetrant inspection line complies with the HB/Z61-98 "Penetrant Testing" standard and the relevant provisions of GJB2367 "Penetrant Testing". The fluorescent penetrant inspection equipment consists of 2 penetration tanks, 2 cleaning tanks, 1 drying tank, 1 post-emulsification penetration tank, 1 manual cleaning tank, and 1 developer tank. The supporting and auxiliary facilities include an electrical control cabinet, an air control system, and connecting pipelines. The overall layout of the inspection line is designed to facilitate the maintenance and cleaning of the entire inspection line. The process layout of this equipment is reasonable, and the process parameters can be set and controlled to meet the needs of quality assurance, ensuring smooth and reliable circulation of parts during the inspection process and facilitating convenient and reliable operation.
3. Process Flow;
Manual feeding - 4-level penetration dripping - cleaning - post-emulsification dripping - 2-level penetration dripping - automatic cleaning - manual cleaning - drying - empty position - powder spraying phenomenon - fluorescence observation - manual unloading
The transfer between each workstation is achieved through rollers, and is completed manually.
4. Process Equipment Overview
4.1. All the box and trough structures are designed and installed in a reasonable, aesthetically pleasing, reliable manner, facilitating safe operation.
4.2. All the boxes and troughs are of independent double-layer structure. The inner trough is made of high-quality 304 stainless steel plate of 2.5mm thickness, while the outer trough is made of 304 stainless steel plate and stainless steel pipes with a fine inner framework.
4.3. All weld seams are welded using argon arc welding and treated. The welding quality is guaranteed with no leakage and the welds have the same color as the base material.
4.4. The main air supply pipelines, each pneumatic spray gun, and the spray powder air path are all equipped with oil-water separators. The filtered compressed air is then directed to each gas-consuming area. Pressure gauges and pressure reducers are installed at each compressed air outlet, and they can be adjusted.
4.5. The troughs are free from distortion, unevenness, scratches, sand holes, bubbles, slag inclusions, and leakage.
4.6. All the main purchased components should have factory certificates of conformity and instructions. All electrical appliances, instruments, and wires should have "production license, certificate of conformity, and inspection certificate".
4.7. The relevant technical parameters comply with the HB/Z61-1998 standard of the People's Republic of China's Aviation Industry "Penetrant Testing" and the relevant provisions of GJB2367 "Penetrant Testing".
4.8. All pipelines (water, electricity, gas) and other auxiliary facilities in the system should be arranged on the rear side of the trough (assembly line).
4.9. Each workstation box and trough is equipped with an embedded independent control panel for controlling the actions within the box and setting process parameters. The placement is reasonable to prevent liquid from flowing in during operation. The control panel is made of brushed stainless steel, and the temperature controller and time relay are digital. The control panel is sealed, and all electrical connections are treated for corrosion resistance and equipped with protective covers. Various instruments have labels, and the installation of all instruments is convenient for disassembly during regular calibration.
4.10. Electrical control system: It consists of 7 intelligent workstation operation control panels. This system can not only achieve semi-automatic process control for each trough but also operate independently.
4.11. The labels on each workstation are in Chinese, and the label material is stainless steel.
4.12. The covers of each box and trough are opened and closed by pneumatic means, with an opening angle of ≥ 90 degrees. Safety devices are set to prevent tipping.
4.13. All display devices and adjustment devices are placed in easily observable positions.
4.14. The pneumatic covers of each trough have locking devices to ensure the safety of operators and components.
4.15. The bottom of the equipment's overall ground is made of stainless steel to form a leak-proof tray, preventing liquid from contaminating the workshop floor.
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