Multi-channel Ultrasonic Flaw detection MUTSX is a multi-channel, distributed and modular precision detection instrument independently designed by Mitech Co.,Ltd. Equipped with electrical automation devices,it can automatically and accurately test, locate,evaluate and diagnose the workpiece’s inner defects(such as cracks,inclusion,stoma and so on)without non-destructive. Adopting the distributed modular architecture,integrates high-precision ultrasound sensing technology and wireless communication networks, it can achieves synchronous control and data acquisition for multiple probes (extendable to hundreds).

Its core functions include:

●Efficient detection: Each channel supports high-frequency repeated emission of ≥ 5000Hz, combined with an automatic scanning mechanism, it achieves full coverage scanning without blind spot for the workpeice’s internal defects such as cracks, inclusions, air holes and so on.

●Intelligent defect recognition: Through presetting process parameters and AI algorithms, the system automatically completes defect localization, quantitative evaluation, grading diagnosis and records the results in real time and generates digital reports.

●Wireless collaborative control: The modules work synchronously through low latency wireless communication to eliminate complex wiring and improve system deployment flexibility and maintenance convenience.

●Industrial-Grade Data Integration: Supports protocols such as OPC UA and Modbus to interconnect with the production line PLC/MES systems, feeding back flaw detection results to the central control terminal in real time.

●Full process automation: Personalized solutions can be customized according to customer requirement. With seamlessly integrates loading/unloading robotic arms and conveyor device, it achieves unmanned operation of the entire process of "detection- analysis-sorting".

Application Fields

The system module is mainly for instrument supporting of automated flaw detection equipment. This equipment mainly applies to the automatic screening production line with internal defects in high-precision, high-volume steel plates, bars, and sheets, online full inspection of key components such as automotive engine parts and aerospace fastener. It can also be paired with mobile automated devices for in-service inspection such as automated detection applications for pipeline welds and pressure vessel wall thickness.

The multi-channel automated flaw detecting system consists of two parts: instruments and machinery. In practical applications, the number of channels and the type of probes should be determined according to the flaw detecting conditions and requirements. During the inspection, the mechanical part feeds the workpieces and aligns them with the instrument probes. The probes are connected to the ultrasonic transceiver modules, each of which is linked to the host computer via an Ethernet switch. The host computer is connected to a display, printer, alarm device, etc. The flaw detection software can display real-time information such as the thickness of the workpiece under testing, the defect echos and the defect locations. The alarm device will sound and light an alarm when abnormalities are detected and the marking sprayer sprays color marks at the defective positions. The inspection process of each workpiece can be saved as a flaw detecting record file for retrieval and report generation. 

●Efficiency zooming: The parallel detection speed of 100 channels is over 100 times faster than manual inspection,and the repeated emission frequency of each channel can reach over 5000HZ. The loading and unloading of workpieces can be automatically completed. Compared with the single channel flaw detector tested by manual, the efficiency has been greatly improved. And it supports 24-hour continuous work.

●Cost Optimization: Reduce the reliance on highly qualified personnel; operators can be qualified after short-term training.

●Artificial flaw detecting requires high standards for operators and the growth of an ordinary operator into a qualified one requires high training cost and long-term accumulation of flaw detecting experience. When workloads are large, a large team of operators are required to work together to complete the tasks. And labor cost is a long-term large expense. Automatic flaw detection reduces the requirements for operator. The entire flaw detection process is automatically completed by the flaw detection software based on presetting the process flow and parameters. Operator do not need to understand the principle of ultrasonic flaw detection deeply, only need simple train which greatly reduces labor costs.

●Quality Assurance: Eliminated manual missed detection, ensuring consistent detection standards and traceable results.

●A well-calibrated automated flaw detection system enables 360° full coverage inpsection of the workpiece without blind spots, operates 24 hours stably without interruption.The flaw detection results are identified, recorded, and saved by the system automatically which reduced a lot of human factors. Manual testing is prone to missed detection, and the quality is heavily depended on the operator's experience and responsibility.

●Process Upgrade: As a key node of the smart factory, it promotes the deep integration of quality control processes with the main production line.

●As a node in the production process, the automated inspection system can integrate with existing production line to control signals, data flow. The flaw detection result can all be organically connected with existing production lines, thereby optimizing the production process.

Install instruments

1. Check if the following items are ready: a. Flaw detector host (chassis+functional modules)  b. PC for installing flaw detection software  c. Network switch (including power adapter) d. Ethernet cable  e. Module power cable  f. Flaw detector host power cable.

2. Turn the power module button of the flaw detection host to the "0" position, and turn the power switches of the I/O module and A/D module to the "OFF" position.

3. Connect the I/O module and A/D module to the power module using a 4-pin module power cable.

4. Connect the network interface of the I/O module to the switch by an Ethernet cable. Connect the network interface of the Test module to the switch by an Ethernet cable. And the switch needs an addtional Ethernet Cablet to connect with PC. 

5. Connect one end of the power cable of the Flaw detector host to the power socket of the power module, and plug the other end into a 220V power strip.

6. Connect the network switch to the power supply.

7. Connect the PC to the network switch and turn it on. Set the IP address of the PC to the 192.168.1. * network segment. Need to avoid IP addresses between 192.168.1.169 and 192.168.1.200.

8. Turn the power switch of the I/O module and A/D module of the flaw detector host to the "ON" position, and turn the power button of the power module to the "1" position. You can hear the buzzer sound and the test host starts working.

9.  Locate the path of the flaw detection software and double-click to open it.

Connect the instrument

1. Double-click the icon to open the software. Click the “Device Config”=> “Factory Config” menu and enter the “Factory Config” view. Click the “Modify Params” button and set the “Test Mode” as “Offline Scan” and then click the “confirm modify”. Click the “Modify Params” button and set the “Total Channel Count” as “4 CHANNEL” , select module 1 in “Enable AD Modules” and then click the “confirm modify”. Exit the software and open again.

2. Click the icon on the toolbar to connect Device. Network is ready when all modules’ connection status bars have turned green.

●This instrument is a precision device. Handle it with care during installation and use to avoid collisions, heavy dust, moisture, strong magnetic fields, oil stains, etc. It is strictly prohibited to use substances with solubility to wipe the shell.

●If the instrument malfunctions, please do not disassemble and repair it yourself. For repair matters, please contact the after-sales service center of MITECH.

●This instrument complies with relevant safety standards. During use, operators should have corresponding skill support to ensure safe operation.