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THE SYSTEM
The Flawmark-EC system consists of the following units
2. SAFETY PRECAUTIONS
The user has to ensure that system should not be switch off
without quitting from system software unless there is any
emergency condition.
3. OPERATION
3.0 Operating Basics
Frequency
Phase
Phase is the angle through which the eddy current signal from
the coil is rotated. Thus, it is not really a fundamental physical
entity, but a process performed on the raw signal. By varying
the phase, a signal which is originally essentially vertical can
even be rotated to the horizontal. The purpose of this will be
apparent while discussing evaluation modes.
Gain
Filters
Thresholds
At the most basic level, Flawmark-EC is, like all eddy current
systems, a comparator. It establishes a threshold for comparison
using a standard defect made on a tube. It then uses this
threshold to compare signals occurring on other tubes.
Whenever you get a signal greater than this threshold, the tube
is deemed to be rejected.
Evaluation modes
Amplitude Mode
Phase Sensitive
The figure at left shows a signal outside the sector. Though the
amplitude is large, it is not ‘detected’, while the smaller signal
in the figure at right is. Along with the amplitudes of these
thresholds, the extents are also adjustable.
When the front end of a tube enters a test head windings or the
rear end leaves the test head, it gives rise to a huge signal. This
signal needs to be suppressed otherwise each tube would land
up in reject bin. The mechanism to ignore these signals is called
signal gating. Two kinds of signal gating are available on
Flawmark-EC: Static gating and Dynamic gating.
Static Gating
tube. Similarly when the rear end of the tube leaves px1, the
gating turns off. There is however substantial length of tube
which has still not yet passed through the test head and any
signals occurring in this length are ignored by the system. This
particular length is untested rear end. In most cases the length
of untested front and rear ends due to static gating is
unacceptable. Dynamic gating allows us to minimize the length
of untested ends to practically reasonable values.
Dynamic Gating
Again, the delays, like the dynamic gating delays, can be either
time-based or distance-based. The latter is the default, as it is
essentially speed-independent. Note, however, that these delays
depend on the encoder. If there is any slip between the tube and
the roller (on which the encoder is mounted) the paint mark
location can go off the actual. There is no solution to this other
than making sure the feeding unit rollers are correctly adjusted
and the tubes pass through the test head smoothly without
hindrance.
vi. Now the user will need to set the marker delays.
There are two methods to set the marker delays:
The system will save the data of the tested tubes in this
file.
3.2.3 Filters
When you run the system software program, you are asked for a
password. Depending on the password entered, you are allowed
into the system at the appropriate security level. Security Level
1 has the highest privileges, and Level 3 has the lowest.
There are only three passwords in the system at any given time,
one for each security level. If one is changed, the old password
is overwritten. Make sure you do not forget your password at
least at level 1!
Visual set and Auto set options can be used to set Gain
and phase for the testing. Auto setting automatically
adjusts the signal with reference to set thresholds. In
visual set, the user can set phase and gain of the signal.
red lines. The first red line from left denotes DF and end
red line denotes DR. Any signals before the start red line
and the signals after the end red lines are not taken into
consideration for the tube detection. The user can finely
tune DF and DR with the help of this tool.
4.1.2 Keyboard
4.2.1 Connectors
Signal outputs for the solenoids are taken out through this
connector.
The top line in the display is the Menu Bar. When the
system starts the cursor is in the parameter panel. Press
F10 to activate the menu bar. Menu cursor is dark blue.
Press Enter to select the menu and menu window opens
disclosing the sub options of the menu. Here white cursor
is used to select the menu item. Press enter to execute the
selected menu item. Bottom lines brief the function of the
Parameter area
Status Area
The white line at the bottom is the prompt line that shows
help hints and message lines.
Signal Area
The gray area of the screen is the slate where all graphics
is displayed. The real time eddy current signals from the
test head for differential as well as Absolute Channel are
displayed in XY and YT modes. Thresholds are drawn
with respect to the selected evaluation mode according to
their amplitudes. Thresholds 1 and 2 are applicable for
the differential channel and they are drawn in WHITE
color. Threshold 3 is drawn in AQUA color on
differential channel signal area. The absolute threshold
Thr Abs is drawn in WHITE color in absolute channel
signal area and Thr Abs1 which is smart balance
threshold is drawn in AQUA color in absolute channel
signal area. When the user selects from various types of
displays all of them are displayed in this signal area.
Replay or text view of the pre-recorded result file is
shown in this signal area.
Hot keys
F1 : Help
F2 – ALT F2 hotkeys
F2 : Show Last Tube
F3 : Capture Screen
F4 : Print Screen
Configure menu
Illustration :
Then the system will prompt for new password and re-
confirmation of new password.
After you finish doing this, you are back in the Config
popup menu, with the new security level showing in the
menu.
Auto set / Visual set helps user to set phase and gain of
the system. It is the powerful feature of Flawmark - EC.
Now a red cross cursor will appear at the tip of the signal
on screen (typically this occurs for the biggest signal).
Move the cursor to a location where you want this
particular signal to be. Press enter again.
Illustration:
That is all. You will find that the gain and phase have
changed so that the next time you pass the same tube that
particular signal will now appear at the designated place.
But F2- Alt -F2 hot key ties can be used to view or print
standard tube data.
Parameter Menu
Record Menu
Log Results on/off option lets you log the results that
come in to disk. It will ask for a filename to store the
results to. The list of file names is displayed. The user
can select from the list or can enter a meaningful name
upto 8 characters without an extension.
The user can set the serial no. for the testing. He will be
automatically prompted for the serial no. entry if serial
no. is not set previously. The user is prompted to fill
printer header information and it is saved to the result file
for future reference. The indication of saved result in
displayed on the screen as a n additional check at the
bottom of the parameter panel.
Current Results
Replay Menu
Show Last Tube (Hot key F2) allows the user to see the
signal over the entire length of the last tested tube in
compressed form. This tool is explained in operating
procedure. The printouts are very important to
compare previous S/N ratios and correctness of
settings.
If the user needs to see front and rear delays, use Alt F2.
View result allows the user to see the saved result file in
text format.
Replay signal
When the user logs on the result file, test data is saved
into record file. This option allows the user to view tube
data in compressed format. XY and YT displays are
available with amplitude and angle information. Start is
with result headers describing the tested lot. The user can
view defect signals and analyze them. Major parameters
are also displayed on the parameter area of the screen.
The user can print the current tube with 'P' option or can
print the entire screen.
Illustration :
Display Menu
Phase allows the user to rotate the phase of the displayed signal
from 0 to 360 degrees. It is important in phase sensitive and
sector modes.
Filter High Pass & Filter Low Pass sets High pass and Low
pass filters. Adjust the filters according to signal frequency and
speed of testing to get good S/N ratio. HP Filter range is 1 Hz –
256 Hz and LP Filter range is 1 Hz – 512 Hz.
FiltSig sets filter on the server board. Set this with respect to
signal amplitude and the speed of testing. If the speed of the
testing is very low you may need to modify this option . Else
keep the option on “Low”. The switches are Low, Medium,
High for this parameter.
Parameter Screen 2
Pulse Source enables the user to test the tube either using the
internal clock of the system or by the external pulses of
encoder.
Dynamic Gate When the tube enters the test head larger
change in the permeability occurs in the vicinity of the coil.
Due to which a large signal is captured. This would be
interpreted as defect. When Dynamic gate is made ON the test
lamp turns on after particular time delay, when PX1 switches
On. This is Delay front .The testing starts after leaving some
front end portion of the tube. When the tube leaves PX1 the test
lamp is off after certain time delay (Delay Rear). Keeping the
Dynamic gate off makes Test lamp On only when PX1 and PX2
are On.
Offline Keypad
The offline key pad allows the user to actually control the
automatic testing process of bar or tubes. The key can be
selected using arrow keys. The selected key is shown in Bright
yellow color. When Enter key is pressed the selected key is
operative. The main parameters are displayed for the user
reference.
The offline keypad is useful for the users who use fully
automatic system.
5. SIZE CHANGE
• Switch off FTS-EC Electronic Unit. Make sure to Quit from the
system before switching off the system.
• Loose both Front and Rear Guide Plates provided for locking
the horizontal movement.
If you have previously tested this size of tube, you can load the
same set of parameters from disk as a starting set of values.
Otherwise proceed as follows :
vi) Set threshold values. You can start with both high and
low threshold values of 50%.
Pass the standard tube through the test head at a constant test
speed with the standard hole pointing upwards (12 o’clock
position). After the tube leaves the test head, press ‘F2’ key on
the keyboard. This will cause a ‘strip chart’ to appear on the
LCD screen, with signals corresponding with standard defects.
Arrow keys (Right and Left arrow) can be used to move a
cursor along the strip chart shown. Position the cursor to the
first standard defect. On the x-y display shown below the strip
chart, the signal vector corresponding with the cursor location
is displayed, and the amplitude and angle readout shown next to
the vector display. Note this angle. Ideally, the vector should
appear vertical on the display. If it does not appear vertical,
change the phase setting of the instrument by the difference of
the shown vector and the vertical .
Repeat step 4 if you need to change the phase above. Finally the
signal due to the standard defect appears vertical at the correct
phase setting. Also note the amplitude of the signal. Adjust
differential gain setting of the instrument and repeat step 4 as
many times as required so that the signal due to the standard
defect appears vertical and its amplitude just crosses the set
threshold for that channel.
Any “grass” (to borrow a term from ultrasonic testing) you see
around the signals due to the standard defects, and which you
cannot attribute to small defects, is noise. You can measure the
amplitude of the noise by moving the cursor to such a location.
Thus, you can calculate the signal-to-noise ratio at this set of
parameters for this standard tube: Simply divide the signal
amplitude by the noise amplitude.
All of the procedure above was for the standard defect passed in
one orientation (e.g. hole at 12 o’clock position on tube). You
must ensure concentricity of test head with respect to the tube
by also passing the tube in three other orientations: holes held at
3o’clock, 6 o’clock and 9 o’clock. Each time measure the signal
due to the standard defect. If there is too much of variation (say
more than 15%) between them, attempt to adjust the coil
platform suitably by very small movements (typically 0.1mm to
0.2mm each time), and run tube in four orientations again. Keep
doing this by trial and error till you arrive at an acceptable
difference. There is little point in going below 10% in most
applications.
Two more steps need to be taken before you can begin testing a
new lot of tubes: Adjusting paint marker delays and adjusting
end suppress settings after changing gating to ‘Dynamic Gate
on’. You might also want to start logging test data to disk
before you begin testing a batch of tubes. These steps are
described in subsequent sections.
7. TROUBLE SHOOTING
7.1 SOFTWARE ERRORS
NOTE :
The user can select displays , view help , log result on-off , pre-
view files only when he is in default display mode. The opening
display of the system is the default display. All most all
operations are carried with that display. The user can not quit
from the system if he is not in the default display screen.
Parameter modification, directly ( by editing the values) or
indirectly (by loading file , auto set etc) is prohibited if the user
is not in the default display screen. ESC key leads the user
towards the default display screen. The user can print one report
at a time. If live signal or live print is on, he can not print
parameters or screen.
Hardware Error 01
Press ‘G’. The user would hear 2 beeps. Press ‘H’. Certain
information would be displayed. The user should note them
down. conform the counts with the Technofour and conform
whether hardware error in ADC card has occurred and it needs
a replacement.
Hardware error 02
Hardware error 01
Result printing ON :
Recorder printing ON :
Printer is busy :
Signal printing ON :
Recorder log enabled :
The user can print either signal or results. The user can print
pre-recorded data if there is no data logging or no live printing.
Pre-recorded data can be viewed or printed if only if tube
testing is off. The user also cannot print the current file or file
in use.
The user cannot 'create' a new file of the same name. In case of
parameter set the user can load pre recorded set. In case of
result and recorder user can print/view/replay the pre- recorded
files.
The user cannot create recorder or result files when Test lamp is
on i.e. tube testing is in process.
Improper signal
Do auto setting and visual setting again.
No data logged
No data is saved so cant view last tube.
If sine wave is not seen than the Drive box or FTS_S card needs
to be replaced. Change the card or drive box as per clauses
mention under precautionary measures while replacing the
PCB.
Test Lamp does not glow Even if Linear speed is found OK.
The Test Lamp turns On only after the Two proximities turn
On. If either of the two proximities do not turn ON then testing
is Impossible. Check proximities connections at junction Box.
Confirm +24 V supply. Also check connectivity between FTS-
EC Electronic Console and interface box. Further confirm the
relays in interface box are operating properly. If Proximity are
needed to be replaced than first remove the Proximity
connections at junction box .
Replace Encoder.
Check Encoder cable.
Replace PCB EC-IO.
Interlock Off
This message can be used to detect trip of saturation or Demag.
If any of them trips , the message is displayed on the screen.
No Charge
The charging mechanism is not activated properly. Time out in
charging a tube.
Stopped
Auto/Single cycle is stopped or system is stopped by a stop key.
ERROR M1-M2
The tube is stuck into M1 and M2. It has left M1 but could not
reach M2. Check tube position.
ERROR M2-P1
The tube is stuck into M2and P1. It has left M2 but could not
reach P1. Check tube position.
ERROR P2–M3
The tube is stuck into P2 and M3. It has left P2 but could not
reach M3. Check tube position.
ERROR M3-M4
The tube is stuck into M3 and M4. It has left M3 but could not
reach M4. Check tube position.
ERROR Bent
The tube is Bent and can not pass through the test head. The
user has to take the tube back by reversing the direction.
Check Test Lamp Status. The signals after this message can not
be saved to the disk. The buffer resets when the Test Lamp is
Off.
• Power Supply
• PCA 6751 Motherboard
• PCB INSIS-ADC
• PCB EC-IO
• PC Back Plane
• PCB INSIS BACK
• PCB DR-PA
• PCB FTS-S
• Drive Box
• Floppy Disk Drive
• Hard Disk Drive
• Power Supply :
Number Function
CN1 FDD connector
CN2 Parallel port connector
CN3 Keyboard lock, LED connector
CN4 USB connector
CN5 24-bit LCD display connector
CN6 36-bit LCD display connector
CN7 LCD inverter connector
CN8 IR connector
CN9 External speaker connector
CN10 Reserved
CN11 VGA connector
CN12 PC/104 connector
CN13 Ethernet connector
CN14 COM2 RS-422/485 connector
CN15 COM2 RS-232 connector
CN16 COM1 RS-232 connector
CN17 External keyboard connector
CN18 ATX power connector
CN19 Reserved
CN20 AT power connector
CN21 Keyboard and PS/2 mouse connector
CN22 ISA gold finger connector
CN23 ISA gold finger connector
CN24 Compact Flash™ card connector
CN25 HDD LED connector
CN26 System reset switch connector
CN27 ATX power button
CN28 Enhanced IDE connector
• PCB INSIS-ADC :
• PCB EC-IO :
• PC Back Plane :
• PCB INSIS-BACK :
• PCB DR-PA :
• PCB FTS-S :
• Drive Box :
Relays 4 No.
PCB Allout 2 No.
PCB Alarm Rec 1 No.
50 Pin Male Connector 1 No.
24 Pin RPC Connector 1 No.
8 Pin RPC Connector 1 No.
3 Pin MS Connector 1 No.
• Relays :
• PCB Allout :
• MS Connector :
When the tube passes through the test head at testing speeds,
essentially two adjacent cross sections of the tube are compared
against one another and the difference is processed by
electronic circuits. The resultant signal has all the information
needed for evaluating the tube against a standard reference such
as a signal due to a drilled hole. In a nutshell, a threshold is set
up as a reference denoting the standard defect. Any signals
crossing this threshold are deemed to be detrimental, and the
tube with such signals is unacceptable.
The screenshots above show the vector (x-y) and Strip Chart
representation of two signals. One signal (the first from left in
the strip chart) is due to a defect. The other (a bunched group in
the strip chart to the right) is due to test piece wobble. The
amplitudes of these two are comparable, and the signal-to-noise
ratio is close to 1.
The same signal is now rotated in phase so that the lift-off (test
piece wobble) is essentially horizontal in the screenshot above
left. The y-component of that signal is nearly zero. The
projection of the defect signal on y-axis is reduced somewhat
due to the angle of the signal with x-axis. However, the loss in
y-amplitude is more than offset by the dramatic improvement in
signal-to-noise ratio.
The tube should then be passed through the system again and
another strip chart obtained on the screen. If the signals are too
high, you can reduce the gain (and vice-a-versa). Finally you
should be able to achieve a high signal-to-noise ratio. Although
S/N of 3 is considered the bare minimum for eddy current tests,
it is good to have a ratio of at least 5 in case of standard tube.
The problem begins when the tube does not pass concentrically.
A hole in a tube passing through the test head at say 12 o’clock
position might pass at a higher distance from the test head
winding immediately next to it compared with the hole passing
at 6 o’clock position. This means that for the same standard
hole, we can get widely varying amplitudes when the tube is
passed in different orientations. Of course this happens only
when the tube passes eccentrically. Which is why some test
standards force you to drill three holes at 120° apart or four hole
90° apart.
This is only one part of the story. If the signal to noise ratio for
an eddy current test is reasonably high, most of the time
repeatability can be shown to be close to 100% on a specific
tube such as a standard tube. (Also refer to the FAQ on signal
to noise ratio for a discussion about the relation between signal-
to-noise ratio and repeatability).
The Demag Coil DC coil has a variable voltage supply, and this
needs to be adjusted by trial and error till an acceptable level of
remanance is achieved. It is possible to over-adjust or under-
adjust to counter effects of magnetization of transport system
rollers.
This also means that if the signal due to a defect is even slightly
lower than the set threshold, the defect will not be marked.
Thus, some defects, which are quite visible on the surface, are
simply not marked, wholly because the signal did not cross the
threshold.
There is another issue too. If the defect is too close to the ends,
the signal due to such a defect is ignored by the system even if
it is much higher than the threshold. (See section on end
suppression.)
This is the other side of the coin, if you just visited the FAQ on
“I see a defect.. but it is not marked”. Flawmark-EC compares
all eddy current signals against a set threshold. If the signal is
higher than the threshold, it is marked by the paint marker.
There are such occasions when you do not see any evidence of
the defect on the surface, but sub-surface discontinuities are
severe enough to cause a paint mark. This is often borne out by
cutting the tube at the correct location. Then the cross section
tells the story. Note, however, that the paint mark can be off the
correct spot at times due to slip between a particular tube and
the driving rollers. Also, at high speeds the mark can stretch for
a larger area. Thus, several cuts may be required to get to the
right spot at times.
If eddy current test frequency is kept too low, although the eddy
currents do penetrate deeper inside the wall, the signal
bandwidth goes down. This has an effect on testing speeds. At
low frequencies, the throughput speeds are low. Typically for
tests at high speeds such as 180 meters per minute, frequencies
below 3 KHz cannot be used. This arises from the requirement
that a typical cross section of tube under test coils should
remain almost static for a period of at least two complete cycles
of test frequency. Thus, although for thicker tubes one would be
tempted to use a lower frequency, it cannot be used at this
speed.