Immersion Systems
Specialists in the design and manufacture of bespoke automated inspection systems since 1987
A versatile system featuring 2-10 AC servo-controlled axes with absolute encoder feedback, ideal for pulse-echo, double through-transmission and phased-array applications. Immersion systems are very configurable, suitable for a wide range of inspections and can be manufactured to almost any size.
Common applications include fan blades, flat-rolled billets, circular engine components, T-stiffeners, metallurgical samples, shaft and tubes, flat or slightly curved panels.
Suitable for the following:
Rigid Framework
The scanning system is built around a rigid framework which supports the tank, rails and bearings for the bridge assembly and Z tower.
Number of safety options
There are a number of safety options – light curtains are commonly fitted surrounding the machine to prevent access to moving parts while scanning.
Axis Motion control
Axis motion is controlled by a USL wireless joystick and USL Scanner software. All linear axes can be fitted with end of travel limit switches.
Precision Components
Gears in the X tip gearbox are helically cut for accuracy and Z tip motor and electronics are sealed to protect from water ingress.
Controlling water in the system
Water in the immersion tank is continuously circulated through cartridge filters (5µm and 100µm) and an ultra-violet treatment unit to limit particulate and bacteriological contamination.
A 3kW heater element is fitted to maintain a constant water temperature and therefore a constant velocity. Float switches are fitted to maintain water level, prevent overfilling and cease circulation and heating should the water level become too low.
Axis Orientation
A typical 5 axis system includes two manipulator axes, these can be oriented as either X tip and Z tip (pictured) or swivel (A) and gimbal (B). These manipulator configurations allow the user to accurately follow non-flat surfaces whilst maintaining the transducer normal to the component surface.
| X-axis | Y-axis | Z-axis | Xt-axis | Zt-axis | |
|---|---|---|---|---|---|
| Travel limits | as specified | as specified | as specified | 360° | ±120° |
| Resolution | 0.01mm | 0.01mm | 0.01mm | 0.02° or better | 0.02° or better |
| Repeatability * | ±0.05mm | ±0.05mm | ±0.05mm | ± 0.05° | ± 0.025° |
| Move accuracy * | ±0.05mm/300mm | ±0.05mm/300mm | ±0.05mm/300mm | 0.05° | 0.01° |
| Speed range ** | 1 to 300mm/sec | 1 to 300mm/sec | 1 to 150mm/sec | 1 to 30°/sec | 1 to 30°/sec |
(*) These figures apply when measuring the axis in one direction of motion.
(**) The speed of the indexing axes during scanning is controlled automatically by the computer according to the motion required and the slowest axis utilised for that motion. Speeds listed are recommended maximums.
To ensure the immersion system suits your specific needs, consider the following options for your system
Turntables
When added to an immersion system, a turntable adds the capability to scan circular components like engine compressor housings, disks or shafts. Turntable scans can be displayed in polar view.
Fixturing method
Head and tail stock options can consist of custom chuck(s) for cylinders, rods, bars or shafts with either a lathe centre or second chuck opposite or a custom boss for components like fan blades. This method of fixturing allows for precise rotational feedback without the risk of slippage associated with roller systems. Driven by AC servo motors with absolute encoder feedback for precise positional accuracy.
Other optional extras
Polycarbonate viewing windows, raise-lower platforms, additional lighting, sound velocity temperature compensation, marker axis, safe lifting aids.
Robots
In certain cases it is possible for robots – with the right tooling – to carry out inspections in an immersion tank. Contact us for more details
Check out some of our Immersion systems in our photo galllery
