Ultrasonic inspection systems and NDT Services since 1983

We are happy to advise you: www.vogt-ultrasonics.de Tel. +49 5139 9815-0 info@vogt-ultrasonics.de

Manual inspection device for the fast and precise spot weld inspection, designed for testing in production and in the laboratory

PHAsis®

Spot weld inspection device with imaging Phased Array Technology

QUICK & INTUITIVE

EXACTLY ON THE SPOT

for laboratory and production

121 ultrasonic elements

integrated test planning

HIGH TEST RELIABILITY

Fig. 1: PHAsisONE manual inspection device with laptop asminimum configuration of the entire system

Fig. 4: Distributed complete system with various PHAsisONE manual inspection systems

PHAsisONE inspection device – high precision with fast imaging evaluation

The PHAsisONE ultrasonic inspection device (fig.1.) is designed for the precise inspection of resistance welded spots of steel- or aluminum sheets. It‘s ide-ally suited for the inspection of 2- and 3- layer joints with a single sheet thickness of 0,6 mm - 5 mm.

PHAsisONE is the first phased array ultrasonic inspection device offering a physical resolution of the spot weld diameter more precise than 0.35 mm. 121 ultrasonic elements are used in an 11 x 11 matrix. More than 700 measuring points per welding spot are recorded during the inspection.

The probe (fig. 3) is connected to the test part by means of the water delay path and its reliable bubble technique. Several standard water delay paths as well as further application-specific water delay paths can be used flexibly, depending on

accessibility and surface quality of the test speci-men. If required, the use of a fixed water delay path (rexolite) is also possible (see technical data sheet).

The inspection time is just a few seconds per spot.PHAsisONE provides data on the diameter of the welded spot, the remaining wall thickness of the welded area as well as the sound attenuation caused by structural transformation as possible evaluation criteria for zinc adhesion bonding.

The compact and robust housing and its low weight of 3.5 kg make PHAsisONE the ideal equip-ment for mobile operation.

Central administration of inspection plans and results

All data is organized by means of PHAsisMANAGER administration software and synchronized with the PHAsisONE ultrasonic inspection device.

If needed PHAsisONE communicates with the customer‘s data base by individually adapted inter-faces.The data and user administration as well as the creation of various inspection plans are clearly designed for easy and fast editing.

PHAsisMANAGER also has an interface for the data import of test plans as CSV files. This simplifi-es the creation of extensive test plans.

Mode „Testing according to test plan“

In this mode, the inspection plans are created by an experienced ultrasonic inspector and made available to the users by means of synchroniza-

Fig. 2: Detailed test report with D-Scan

PHAsisMANAGERAdministration software

PHAsis PHAsisONEultrasonic inspection devices with PHAsisDEVICE inspection and evaluation software

MS-SQL Expresswith data base

remoteor local

remoteor local

tion with the individual inspection devices. As a result, the users no longer have to make any test settings. They only inspect the spot welds using the visually displayed test plan. This means that even test personnel without in-depth knowledge of ultrasonics can perform reliable testing.

Mode „Free Testing“

The mode „Free Testing“ enables a fast inspection of various spot welds, detached from set inspec-tion plans (refer to fig. 5). Therby the user has still access to the full functionality as known from the mode „Testing according to test plan“.After the inspection, the results of the free testing can be transfered into an inspection plan and a standard inspection.

PHAsis ®

Fig. 3: Phased array ultrasonic probe with a selection of water delay paths

Intuitive software for a fast inspection

The PHAsisDEVICE inspection and evaluation software on the PHAsisONE device is specifically designed by VOGT Ultrasonics for quick use during production. The intuitive operation guarantees a minimum need of training.

PHAsisDEVICE supports the customer with a live C-Scan and time-of-flight-based alignment pointsfor the optimum focussing of the probe on thespot weld to be inspected (fig. 6).

The imaging display of the phased array techno-logy ensures the safe evaluation of the inspection results.

The created display of the spot weld with coloured depth imaging of the welded areas (D-Scan) shows defects in the welding, e.g. pores or too small welding spots. By freezing the D-scan PHAsisONE automatically provides an evaluation proposal (fig. 7).

Fig. 5 (left): Configuration

free testing mode

Fig. 6 (middle): Live-C-Scan for

positioning and vertical focussing

of the probe on the spot weld

surface

Fig. 7 (right):Automatically

created evaluation proposa

PHAsis in use with robot technology

We supply the following tools for use with robots:

▪ Communication interface: Automation inter- face, PHReAP (REST-interface), interface

licence / interface licence for remote control for every PHAsis ultrasonic inspection device, incl. detailed description

▪ Probe holder incl. water coupling nozzle forPHAsis probe diameter 24 mm for mountingon a robot

▪ Reference plate with reflectors for systemmonitoring and calibration

▪ Export interface for test results, importinterface for test plans

▪ 4 distance information for vertical alignmenton the spot weld surface via automation inter-

face

Furthermore we also offer a Cobot, which can be used with the PHAsisONE ultrasonic inspection device as a unit for the inspection of joints. This is a Franka robot, which can be easily teached by an experienced inspector or an inspection su-pervisor. The robot and PHAsisONE can be used as a mobile unit and achieves excellent results.

Such robots can make spot weld inspection and longitudinal weld seam inspection less expensive. Instead of manually testing with one device, the inspector can test several components simulta-neously with 2-3 Cobots. We would be pleased to present the concept to you.

Module Longitudinal Weld Seam Inspection

PHAsisONE is also ideally suited for the inspec-tion of longitudinally welded seams, e.g. Arplas® weld seams or short-lined weld seams (see Fig. 8). Longitudinal weld seams with a length of 3 mm to 12 mm can be tested. For this purpose, the same probe is used as for the testing of spot welds. Furthermore, up to two partial lines (maximum interruption length can be set by the user) can be defined as one seam. Fig. 8:

Automatically generated evaluation proposal for longitudinal weld seam (e.g. Arplas®)

Click here for our YouTube Channel

Here you will find PHAsis product videos and

application examples

PHAsis ®

Fig. 9: PHAsis inspection device, operated by a robot. The positioning on the spot weld is optimized by a camera-supported detection of the spot weld position, a regulation of the contact pressure and a precise adjustment based on the ultrasonic signals.

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Make an appointment for a live presentation with us!

VOGT Ultrasonics GmbH Ehlbeek 15, D-30938 Burgwedel, Tel: 0049 5139 9815-0 info@vogt-ultrasonics.de www.vogt-ultrasonics.de

Proven quality Accredited as independent test laboratory acc. to DIN EN ISO / IEC 17025 Certified acc. to DIN EN ISO 9001 and DIN EN 9100

Manual inspection device PHAsisONE

Dimensions 220 x 200 x 90 mm3

Weight 3,5 kg incl. Battery

Display 7“ TFT, LED Backlight480 x 800 Pixel, 9:16

Housing CNC manufactured aluminium housing

Protection Class IP 64

Battery-Operation Yes, lithium-Ion 14,4 V with 69 Wh

Battery Life ca. 5 hours

Phased Array Interface IPEX 30046 Plug-in connection

Phased Array Channels 16/128 PR

Digitization Rate 100 MHz

Amplitude Resolution 16-bit

Network Connection Ethernet 10/100RJ-45

Data Interface USB Type A

Max. IFF 10 KHz

Video Output VGA 1024 x 769, HD15

Max. Pulse Width +/- 100 V (200 V peak to peak)

Band Width (-3dB) 0,5 - 25 MHz

Pulse Width 5 ns - 10,2 µs in 2,5 ns steps

Frequency Filter Digital

Focal Laws > 700

Power Supply 100 - 240 VAC,50 Hz - 60 Hz

Operation Temperature -10°C bis zu 40°C

Storage Temperature -20°C bis zu 60°C

PHAsis Software Solution

� Administration of specific ultrasonic parameters

� Administration of specific evaluation parameters

� Creation of inspection plans for the production (for

the easy and rapid processing by the inspectors)

� Spot weld specific setups due to allocation/combi-

nation of different parameters (evaluation parame-

ters, ultrasonic parameters, sheet combinations)

� Individual colored result display

� Inspection plans available on all PHAsis inspection

devices by synchronisation

� Free testing (testing without inspection plan) for the

use in the laboratory and setup

� Creation of test plans based on the results of the

free testing

� 2 different evaluation methods (backplane, joining plane)

� Clear result display for each processed inspection

plan respectively inspection series with the free

inspection

� 2 different report types (detailed, compacted)

� The reports can be exported as Word-, Excel-

or pdf-document

� Multiple interfaces such as test plan import, result export, communication interface for automated inspections

PHAsis Software Solution

� User administration in three right groups

� Device administration

� Material administration

� Administration of sheet combinations

ProbeType Phased Array 2D Matrix

Numer of Elements 11 x 11 arranged in square form

Cable Long-life 2,5m; 5m for robot applications

Nominal frequency 12 MHz 20 MHz

Inspection Area 9 x 9 mm2 11,7 x 11,7 mm²

Physical Resolution better than 0,35 mm 0,45 mm