Ultrasonic Inspection Station for Castings Spheroidization Control

Purpose of the device

The device has been designed for effective quality control of castings using ultrasonic technology. The station enables inspection and imaging of proper spheroidization, as well as verification of the part shape in accordance with process requirements. This solution helps maintain high quality standards and reduces the risk of defective components being passed on to subsequent stages of production.

Operating description

After the parts are placed in the nests and the cycle is started by the operator, the station performs a fully automated inspection process, including the following stages:

- transport of the base with the parts to the inspection area;

- application of oil through dosing nozzles at the contact points between the probes and the part surface;

- lowering of the probes and performing the measurement of the spheroidization level of cast iron;

- return of the system to the home position and marking of compliant parts;

- automatic placement of accepted castings into dedicated chambers of the transport container.

The base is equipped with two part nests – left and right – reflecting the shape of the parts. Integrated sensors check the correct positioning of the component before the inspection begins.

Before measurement, the contact area between the probe and the part is wetted with oil, which eliminates air bubbles and ensures proper inspection conditions;

The degree of spheroidization is checked by 6 ultrasonic probes, which perform measurements at designated points on each casting;

Ultrasonic probes analyze the propagation speed of the ultrasonic wave in the material;

A speed above 5550 m/s confirms the correct spheroidal structure of the cast iron;

After the inspection is completed, parts that meet the requirements are automatically marked and placed into a transport container.

The station is equipped with a Siemens PLC controller and a 7-inch HMI panel, ensuring convenient and intuitive operation.

The machine is built on a welded steel support structure, ensuring durability and stable operation.

The device uses a number of advanced safety solutions, such as light curtains and safety locks. A stopping distance measurement of the light curtain was also carried out, which made it possible to ensure a high level of protection for both the operator and the process.