Our customized PROline ultrasonic inspection system for automated weld seam testing of differential gear wheels.

In the production of differentials, the requirements for weld seam testing get more and more complex. Based on years of experience, VOGT Ultrasonics developed a complete system for ultrasonic testing of differential gear wheels by using immersion technique. The most incisive feature of the new solution developed within the PROlineCUSTOM product line: With just a few modifications, it can be adapted to the demanding, customer-specific requirements. It detects critical defects within a weld seam fully automated, fast and safe.

The flexible inspection system can work either in a production line or as stand-alone solution. Different types of differential gear wheels with similar physical inspection requirements can be tested automatically. The modification is carried out by component-specific adapters, regardless of lot sizes, quick and easy. In a next stage of expansion, the system can optionally be equipped with an automatic component supply by a robot.

Marking of defective components included

The analysis software is used for defect valuation and documentation. The testing system also offers the possibility to mark defective components fully automatic. In the stand-alone version, the system operator manually places the test component on the adapter in the immersion tank and loads the corresponding test plan. The inspection starts after a component query, a surface echo detection and a positive scan of the safety circle. By means of a spiral scan, the probe scans the weld seam horizontally while the component is rotating. If a weld seam is identified as being defective, the component is declared as “not OK”. In addition, a clear indication appears on the display. The tested component is automatically color-marked as “not OK” and the system operator separates the component. If the test result is confirmed as “OK”, the operator will place the component in the subsequent process.