SEMINAR GRINM R&D Laboratory on Industrial Demand General - - PowerPoint PPT Presentation

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SEMINAR GRINM R&D Laboratory on Industrial Demand General - - PowerPoint PPT Presentation

May 09, 2023 505 likes •930 views

SEMINAR GRINM R&D Laboratory on Industrial Demand General Research Institute for Nonferrous Metals Integrated NDT Systems Michael Krning SYSTEMS ASSETS CASE STUDIES Integrated NDT Systems SEMINAR GRINM R&D Laboratory on

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SLIDE 1

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

Michael Kröning

SYSTEMS ASSETS CASE STUDIES

Integrated NDT Systems

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SLIDE 2

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

NDT – DRIVEN BY

Technical Safety Requirements, Structural Reliability, Preventive Maintenance, and Off-line Quality Control

Manual weld inspection Final inspection of components after induction hardening Final inspection of gear wheels after grinding

Integrated NDT Systems Post-manufacturing testing

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SLIDE 3

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

PARADIGM CHANGE by AUTOMATION (Robotics) MICROELECTRONICS (Instruments) COMPUTING (Real-time advanced signal processing) IT(Asset management; distributed systems;

NDT – DRIVEN BY QUALITY MANAGEMENT

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SLIDE 4

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

MANUFACTURING End Control Process Control MAINTENANCE In-service Inspections Health Monitoring

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SLIDE 5

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

PRODUCTION INTEGRATED NDT

BENEFITS IN-LINE INSPECTION

  • 100% Part Inspection
  • International Product Liability
  • Controlled Production

INTEGRATED PROCESS CONTROL

  • Capable Processes
  • Defect Prevention
  • No Rejections

CHALLENGES R & D

Networks New Methods System Engineering Availability & Maintenance

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SLIDE 6

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

AUTOMATION

Mass Production in “Modern Times” Charlie Chaplin USA, 1936

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SLIDE 7

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

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SLIDE 8

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

UT, μ-NDT, NDT Systems

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SLIDE 9

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

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SLIDE 10

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

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SLIDE 11

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

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SLIDE 12

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

Ultrasonic testing

Flow direction

Automated Final Inspection Line (FIL) for Railroad Wheels at ОАО NTMK Wheels and Tires Shop

  • Chemical treatment of the wheel surface.
  • Identification of wheel marking.
  • Control of wheel geometry
  • Visual inspection of surface defects
  • Ultrasonic inspection of internal flaws.
  • Magnetic particle inspection
  • Hardness testing of the wheel rim butt-end.
  • Roto-blast hardening of the wheel disk.
  • Anticorrosive protective coating of wheels.

9 Process Steps Line Cycle: 70sec/wheel

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SLIDE 13

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

IN-LINE WHEEL INSPECTION 1 Wheel/min

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SLIDE 14

Wheel Inspection System

Modul B, TEG Modul D, NTMK Modul C, TEG

Integrated NDT Systems

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

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SLIDE 15

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

Controlled Mass Production Injection molding of plastics with gas injection (GIT)

reject accept

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SLIDE 16

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

Controlled Mass Production

94 GHz radar module, frequency-modulated, (developed by Fraunhofer IAF)

VCO – Voltage Controlled Oscillator MPA – Medium Power Amplifier LNA – Low Noise Amplifier IF – Intermediate Frequency

MPA LNA OUT VCO IF MIXER 50 W

Monolithically Integrated 94 GHz FMCW Radar Chip

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SLIDE 17

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

Controlled Mass Production

Layout of GIT process monitoring with radar sensor Process steps identified by characteristic signal changes

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SLIDE 18

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

PI NDT – a tool of automated quality controlled production:

Process and/or in-line Integration Automation Information Management Real-time quantitative data processing High reliability and availability Remote system maintenance

Management Controlled Quality Costs

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SLIDE 19

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems Benefits Tasks

Process analysis and modeling Process monitoring Process optimization and control

Fast collecting of process and quality data

  • > Fast and inexpensive modeling and validation

Only good material goes “out the back door” Fast detecting and locating of process disturbances Process limits can be completely exploited Automated data acquisition, analysis, interpretation

  • > Avoiding human error sources

Establishing and maintaining the process optimum in respect to quality and costs Fully automated, self-controlled production

Increased reliability, increased productivity, reduced costs

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SLIDE 20

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems Process

Control device Actuator Manipulated variable

Input Output

Lead signals Disturbance variables NDT sensors NDT sensors Control variable Control Monitoring NDT sensors Control Monitoring Control Monitoring

PI NDT: Process Integrated NDT

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SLIDE 21

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

PI NDT: Quality and Process Control

Classical Quality Control

(SPC - Statistical Process Control)

Classical Process Monitoring and Control

With quality characteristics

  • f the product

With measurable quantities

  • f the process

Off-line, discontinuous, delayed On-line, continuous, in time Observation of quality degradation Process disturbances? Observation of process disturbances Quality degradation? Quality Control Cycle Process Control Cycle Corrective actions Corrective actions

Process Integrated NDT Quality and Process Control

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SLIDE 22

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems Micro-Magnetic Sensor on a robotic arm above the moving strip In-line monitoring of mechanical properties (Rm, Rp0.2, hardness) Feedback Control in Thin Strip Production

  • Production of steel

strips of several kilometers length with uniform mechanical properties

  • Feedback control
  • f process parameters

like oven temperatures, strip feed, etc.

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SLIDE 23

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

PI NDT: Quality and Process Control

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SLIDE 24

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems Ultrasonic sensor integrated into the screwnut of a power screwdriver US screwdriver Control system Task: Control of Power Screwdrivers Precise determination of pre-stressing force as the control variable for power screw-driver control Solution: Monitoring of screw elongation instead of screwing torque

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SLIDE 25

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

HEALTH MONITORING

BENEFIT

through

Continuous Degradation Monitoring

  • Maintenance when needed
  • Optimized System Availability
  • Maximal System Exploitation
  • Advanced Maintenance

Strategies

CHALLENGE

for

System Development

  • No false calls
  • Validated PoD
  • No Degradation of Structure

and System Operation

  • Redundancy of System Safety
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SLIDE 26

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

HEALTH MONITORING

Telemetric Antenna

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SLIDE 27

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

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SLIDE 28

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

HEALTH MONITORING

S = 2.0 mm S = 0.25 mm narrow crack (0.25 mm)

  • pen crack (2.0 mm)

Calculated Sonograms

Modeling helps to understand wave generation and propagation as part of the sensing principle

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SLIDE 29

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

HEALTH MONITORING

passive (acoustic emission) active (ultrasound pulse echo) Sensor Sensor / Aktuator

SHM with guided waves Condition Based Maintenance

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SLIDE 30

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems Plastics with embedded piezoelectric fibers Fiber thickness < 100µm

Image courtesy of Fraunhofer-ISC, Würzburg

Structure Integrated Sensor System

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SLIDE 31

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

HEALTH MONITORING

The sensors are sensitive to the orientation of the incoming wave ...

Parallel to fiber orientation: low sensitivity Perpendicular to fiber orientation: high sensitivity

... and thus, providing new opportunities for flaw detection

Source of acoustic waves

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SLIDE 32

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

ULTRASONIC PIEZOFIBER SENSOR STRUCTURE

Fiber orientation Electrodes Piezoelectric Fibers

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SLIDE 33

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

PRODUCTION INTEGRATED NDT

NDT in Asset Management

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SLIDE 34

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

NDT in life cycle management

Planning

  • Design for testing
  • Plan sensor

integration

Construction

  • Develop QC system
  • Establish test methods
  • Create Base line data
  • Benchmark data

Operation

  • Inspection in

defined periods

  • Inspection

frequency based on age

  • Monitor and

provide alerts

  • Provide strategy

for maintenance

Retirement

  • Inspection of

vulnerable parts

  • Verification of

models

  • Improve test

methods

NDT SUPPORTED ASSET MANAGEMENT

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SLIDE 35

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

At present, NDT data is typically not part

  • f any enterprise IT solutions

GAP

NDT SUPPORTED ASSET MANAGEMENT

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SLIDE 36

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

Testing NDT Analysis Growth Model Decision model Repair / Withdraw

  • Typically offline activity
  • Summary data is input into an enterprise system
  • Significant productivity and cost improvements could

be realized through integration with EAMs NDT SUPPORTED ASSET MANAGEMENT

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SLIDE 37

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

EAM Software

  • Critical portion of Asset

Management activity not captured

  • Significant upside

potential for first mover NDT SUPPORTED ASSET MANAGEMENT

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SLIDE 38

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

Market Size

  • US $ 1.3 billion in 2007
  • US $ 1.8 billion by 2012
  • Utilities account for a significant portion

NDT SUPPORTED ASSET MANAGEMENT

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SLIDE 39

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Integrated NDT Systems

Thank you!

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SLIDE 40

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Day 2: Organization and Networks Speaker

9.00 9.30 10.00 10.30 11.00 11.30 12.00 12.30 13.00 14.00 14.30 15.00 15.30 16.00 16.30 17.00 Welcome Address with Minutes of Last Day Recommended Laboratory Structure of Activities Human Resources – Ethics, Responsibilities, Education, Training and Certification Coffee Break Methods I - ET, MT, PT, TT, VT X-ray, Betatron UT, μ-NDT, NDT Systems Open Round Discussion (Questions) Lunch Break Applied Technologies and Capability Networks Knowledge Strategies and Education Coffee Break Added Value Chain in Applied Science R&D Driven by Demand – a Project Analysis Concluding Minutes End of Second Day NN Kröning Klimenov Vavilov Klimenov Kröning all Kröning Klimenov Vavilov Kröning to be appointed

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SLIDE 41

GRINM

General Research Institute for Nonferrous Metals

SEMINAR

R&D Laboratory on Industrial Demand

Day 3: CASE STUDIES & NEXT STEPS Speaker

9.00 9.30 10.00 10.30 11.00 11.30 12.00 12.30 13.00 14.00 16.00 Welcome Address with Minutes of Last Day Case Studies: Betatron for NDT Advanced UT and New Instruments Coffee Break Thermography for Surface Characterization NDT System for In-line NDT International Cooperation Practice Open Round Discussion (Questions) Lunch Break Next Steps and Seminar Evaluation End of Third Day NN Klimenov Kröning Vavilov Kröning Klimenov all NN