CT for the production floor: Recent developments in Hard- and Software for industrial CT Systems

Transcription

1 CT for the production floor: Recent developments in Hard- and Software for industrial CT Systems GE s Industrial X-ray and CT Forum, Cologne July 7 th 2015 Oliver Brunke GE Sensing & Inspection Technologies GmbH, Wunstorf, Germany Oliver.Brunke@ge.com Imagination at work Copyright 2014 General Electric Company Inspection Technologies 1

2 After more than one decade of CT application in Labs, industrial CT is now moving to drive productivity directly on the factory floor 1. The solution has to cover failure analysis/ndt & Metrology applications 2. Target applications: Cylinder heads & crank cases & turbine blades & fan blades & The system should be capable of fast, automated and reliable pass/fail decisions 4. The inspection solution should drive productivity, cost and reduce Cost of Quality x 2

3 Overview 1. v tome x c: The 450kV CT solution for production applications now with scatter correct for groundbreaking 3D CT data quality 2. 3D Metrology with CT: applications and challenges 3. speed scan CT: ultrafast helix Computed Tomography for casting process productivity and quality improvements Copyright 2014 General Electric Company 3 Inspection Technologies 3

4 GE s phoenix v tome x c: The 450kV CT solution for production applications scatter correct for groundbreaking 3D CT data quality Imagination at work. Inspection Technologies 4

5 scatter correct: fundamentals Cone beam CT (3D) is fast but scattered radiation can affect the image quality Fan beam CT is not affected by scattered radiation but is slow GE s scatter correct utilizes the advantages of both methods

6 scatter correct: the result 1. 9 min 3D-Cone beam CT with imaging artefacts caused by scatter min 2D-Fan beam CT without imaging artfacts 3. scatter correct: speed of 3D-CT with combined with quality of 2D-CT

7 scatter correct process flow First CT scan All further scans of the same sample type Step 1 Acquire projection data Step 1 Acquire projection data Step 2a Acquire correction data (only once per part type) Step 2 Reconstruction of corrected dataset Step 2b Apply correction Step 3 Reconstruction of corrected dataset

8 scatter correct application examples, Turbine blade CT slice without scatter correct CT slice with scatter correct 8 GE Title or job number 7/8/2015

9 scatter correct application examples, Al die casting uncorrected CT scan scatter correct 9 GE Title or job number 7/8/2015

10 scatter correct application examples: Al die casting CT histogram without scatter correct CT histogram with scatter correct 10 GE Title or job number 7/8/2015

11 Das Bild kann zurzeit nicht angezeigt werden. Das Bild kann zurzeit nicht angezeigt werden. scatter correct application examples: phone from 1962 uncorrected CT scan scatter correct 11 GE Title or job number 7/8/2015

12 scatter correct: Performance and productivity improvements CT Quality scatter correct 3D CT Fan beam 2D CT conventional 3D CT Acquisition speed 2D fan beam CT data quality is superior regarding scattering artifacts 3D cone beam CT is 100 x faster than 2D fan beam CT scatter correct combines the productivity of 3D CT with the data quality of 2D CT

13 phoenix v tome x c 450 HS Das Bild kann zurzeit nicht angezeigt werden.

14 Das Bild kann zurzeit nicht angezeigt werden. Das Bild kann zurzeit nicht angezeigt werden. Das Bild kann zurzeit nicht angezeigt werden. v tome x c 450 HS: scatter correct & quick pick 450 kv minifocus X-ray source scatter correct for DXR 16 flat panel detector 4 axis granite based manipulator (X b,y s,z s,r s ) quick pick part exchange system (optional) for automated processing of up to 25 parts Gripper & box design can be adopted to customer parts

15 Overview 1. v tome x c: The 450kV CT solution for production applications now with scatter correct for groundbreaking 3D CT data quality 2. 3D Metrology with CT: applications and challenges 3. speed scan CT: ultrafast helix Computed Tomography for casting process productivity and quality improvements Copyright 2014 General Electric Company 15 Inspection Technologies 15

16 Das Bild kann zurzeit nicht angezeigt werden. GE s v tome x m metrology edition: Precise 3D measurements referring to VDI 2630 guideline Imagination at work. Copyright 2014 General Electric Company Inspection Technologies 16

17 Das Bild kann zurzeit nicht angezeigt werden. phoenix v tome x m 3D metrology Industrial CT process control with extremely high accuracy and reproducibility for Dimensional measurements / wall thickness analyses Nominal-actual CAD comparison Reverse engineering / tool compensation

18 Das Bild kann zurzeit nicht angezeigt werden. phoenix v tome x m metrology edition: System features to ensure measurement precision Designed to ensure long term stability Granite based precision manipulator Temperature stabilized tube and detector Direct measuring system Automatic voxel calibration tool Test phantoms and automatic procedures to determine the specific system values

19 Das Bild kann zurzeit nicht angezeigt werden. Influence of CT system components on measurement accuracy X-Ray tube: Focal spot position: - Focal-object and - Focal-detector-Distance Manipulator: Linearity of magnification axis Detector: Is the detector ideal regarding its geometry? May 12 th 3:30 pm: System requirements for Metrology CT

20 Das Bild kann zurzeit nicht angezeigt werden. Das Bild kann zurzeit nicht angezeigt werden. Das Bild kann zurzeit nicht angezeigt werden. Das Bild kann zurzeit nicht angezeigt werden. Compensation of residual errors to reach < 4 µm accuracy 1. Optimize global geometry: Focal- Object- and Focal-Detector- Distance 2. Adjust remaining non - linearity of manipulator 3. Identify and compensate local geometry: measurement of detector (non) - flatness

21 Compensated Measurement Results Distance error of sphere centers, SD [mm] Non compensated Incl. compensation 0,004 0,004 0,002 0,002 Distance error SD, mm 0,000-0,002-0,004-0,006-0,008-0,010-0, ,000-0,002-0,004-0,006-0,008-0,010-0, ,014-0,014-0,016 Calibrated sphere distance, mm -0,016 Calibrated sphere distance, mm Sphere distance error - v tome x m metrology edition : SD MPE = 4µm +L/100

22 Overview 1. v tome x c: The 450kV CT solution for production applications now with scatter correct for groundbreaking 3D CT data quality 2. 3D Metrology with CT: applications and challenges 3. speed scan CT: ultrafast helix Computed Tomography for casting process productivity and quality improvements 22

23 GE s speed scan CT technology: Das Bild kann zurzeit nicht angezeigt werden. Automated high-speed CT for 3D mass production process control Imagination at work. Copyright 2014 General Electric Company Inspection Technologies 23

24 speed scan CT 64 Das Bild kann zurzeit nicht angezeigt werden.

25 Das Bild kann zurzeit nicht angezeigt werden. speed scan CT 64 Several hundred times faster than conventional industrial fan beam CT Down to 1 minute cycle time with highly automated workflow Ideal for casting process optimization based on statistics Reduced reject rates in serial inspection GE speed ADR integrated in VGInline for optimized 3D defects detection Scanning volume up to 500 x 900 mm Robust design for harsh industrial environments July 8 th 12:00: F. Hansen et al.: speed scan at VW foundry 25

26