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Following the successful RapidScan2 instrument
from Sonatest NDTS, the RapidScan3D now
offers the capability to scan 3 dimensional
structures quickly and accurately using
a precision coordinate measurement arm.
Using the same high performance ultrasonic
system of the RapidScan2 and user friendly
software, complex structures can be scanned
and evaluated. The RapidScan3D offers a
complete and integrated ultrasonic scanning
system. When scanning medium to large areas,
full A-Scan capture is essential to avoid
re-scanning regions during detailed analysis,
whilst offline analysis tools improve production
throughput. The RapidScan3D has full A-Scan
capture as standard, and a complete suite
of tools for Ultrasonic data review and
post-processing. Complete control over gating
and colour maps after scanning means that
you will only ever need to scan a part once,
and powerful defect analysis functions allow
indications to be sized, annotated, saved
and printed for reporting. The RapidScan3D
operates in pulse-echo mode, and synchronizes
with the scanning arm to achieve the fastest
scanning rates possible. Having a 128 channel
architecture allows large, high resolution
Ultrasonic arrays to be employed for large
area coverage. Fast, integrated data capture
and high quality analogue electronics ensures
the best possible quality, resulting
in enhanced defect detection. The patented
Array Wheel Probe is available for
use with the RapidScan3D as well as a growing
range of sensors designed for collecting
the highest quality data, quickly and efficiently,
for rapid analysis of parts for aerospace
and other highly demanding applications.
Using Sonatest NDTS proprietary coupling
material, the ultrasonic probe does not
require coupling gels or large volumes of
water. A fine water mist is all that is
needed to ensure consistent high quality
coupling to most surfaces.
Productivity
Traditional NDT scanning can be time consuming
and difficult to set up, sometimes requiring
expensive tooling designed for the inspection
of a part, especially for 3 dimensional
scanning. The RapidScan3D provides the capability
to scan 3D objects previously only found
in expensive contour following scanning
systems.
The RapidScan3D software wizard allows the
operator to quickly choose a part to scan
easy to reference the NDT data to the structure.
from a library on the instrument. These
can be a mixture of parts with 3D CAD models
and parts generated from pre-defined “stock”
objects. The wizard then presents compatible
inspection tools for different regions of
the part. Some regions will require fast
large area coverage using a large Wheel
Probe, where other regions may require smaller
probes for radius or stringer inspections.
The instrument settings are then automatically
set up for the inspection and the part can
be scanned immediately. Using the scanning
arm to inspect the part is fast and efficient,
ergonomically designed specifically to follow
complex 3D shapes: the time taken to perform
the inspection is as short as possible.
Different arm sizes are available with working
envelopes from 0.6m to 1.8m, all with exceptional
accuracy and repeatability. The RapidScan3D
also supports multiple part and arm positions,
so large parts can be scanned in one session
by repositioning the arm or moving the part
if necessary. After scanning, there is no
need to re-scan the part again. All the
A-Scan data for the inspection has been
stored, and can be reprocessed as with the
RapidScan2. All the inspection gates can
be adjusted after the scan, and even completely
new C-Scans can be made. The evaluation
tools are designed to be fast and intuitive
to use enabling quick evaluation of the
part. The Ultrasonic scan can be shown mapped
onto the 3D part, allowing a truly intuitive
method for quickly qualifying defects based
on their position within the mechanical
structure. Results can easily be disseminated,
and interpreted by colleagues without NDT
experience.
Array Sensors
Sliding Probe
The sliding probe features a 0.8mm pitch
array with 64 elements in a small compact
sensor. This hand held probe is designed
to work with the Faro arm to scan areas
with tight access, but has the same area
coverage as a Wheel Probe. This sensor is
designed to work with a water feed system
to ensure excellent coupling for parts with
tight radius of curvature.
Sonatest NDTS offer a range of sensors for
the RapidScan2 and RapidScan3D instruments.
Our proprietary rubber coupling allows for
high quality Ultrasonic data to be captured
without the need for coupling gels or large
volumes of water. The rubber has
been designed to closely match the properties
of water, providing excellent low loss coupling
into the part. The conformable Wheel Probe
tyre provides good performance on rough
surfaces, and rolls over debris or fasteners
without causing damage. Good quality scan
data is available even around bolt holes
and rivet heads.
The sliding probe features two probe positions
which allow horizontal and vertical parts
to be scanned easily.
The RapidScan3D software is able to work
with a number of probe configurations which
may be switched during an inspection making
it easier to scan components with difficult
access. Ergonomic design can reduce operator
fatigue increasing productivity still further.
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RapidScan3D workflow
For many structures, a stock object can
be used to generate a model for a region
of the structure to be inspected. However
for applications where added value is gained
from correlating the scan data with the
detailed geometry of the part, the RapidScan3D
can work with your 3D CAD data. For inspections
where CAD data is not available or not required,
the RapidScan3D allows stock object parts
to be created which in many cases gives
an excellent 3D representation of the part
to inspect. Planar surfaces are found on
many structures, and often surfaces with
mild curvature can be approximated to planes
without any loss of accuracy. Cylindrical
surfaces are found in leading and trailing
edges, and fuselage sections in aerospace
structures, as well as tubes and pressure
vessels. Radom structures and pressure vessel
end caps are scanned using the Dome surface
model. The software wizard allows the operator
to adapt any of the parts in the stock object
library to provide the best fit to the structure
to be inspected. By positioning the Wheel
Probe, or other inspection tool at certain
points on the part, the software will fit
the stock object to the position and geometry
of the structure. The example below shows
a C-Scan mapped onto a portion of a cylinder.
For demanding production NDT it can be critical
that faithful defect sizes are reported.
Sonatest NDTS offer a service to convert
the surfaces of interest on your 3D model
into 2D C-Scan maps which guarantee the
best possible preservation of defect size
and shape using our novel Finite Element
algorithms. RapidScan3D uses novel surface
unwrapping algorithms to ensure that the
C-Scan you evaluate is mapped exactly to
the surface of the part you have inspected.
This model is then provided as an object
that can be installed in the RapidScan3D
wizard. As the part is scanned, the ultrasonic
data is automatically presented in a large
area 2D C-Scan for easy interpretation,
ready for use with evaluation procedures
as found with conventional 2D Ultrasonic
scanning. The live C-Scan presentation shows
areas scanned to ensure 100% part coverage.
The instrument always selects the highest
quality raw data for the C-Scan by choosing
the A-Scan with the highest amplitude, even
if a location on the scan is covered many
times from different directions.
After scanning the part, the C-Scan map
can be displayed on the 3D image. This powerful
feature allows defects in the C-Scan to
be accurately and intuitively referenced
to the 3D structure. The example below has
been provided with the kind permission of
Airbus UK, and is a RapidScan3D scan of
a composite spar structure. In this example,
the part is scanned in three positions and
the time of flight C-Scan is rendered onto
the CAD model of the part.
The 3D view may be rotated and zoomed by
the operator, and cursors on the conventional
2D scan also appear on the 3D model so that
it is easy to reference the NDT data to
the structure.
Wheel Probe
Adapted from our patented Wheel Probe technology,
the
RapidScan3D wheel probe offers exceptional
performance for fast large area coverage.
It has been specifically designed for ergonomic
handling, and incorporates a 0.8mm pitch
array with 64 elements for high resolution
C-Scan imaging, and a low pressure coupling
tyre.
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