FAQ

Thermal Profile

The sensor has 22 lines across the field of view. The ideal position is in the center of the field of view for the max temp. Installing the system requires a couple of iterations to get the position correct. There is an option to add a laser pointer to the TPS scanning head.

The housing material is non ferrous. Since the unit is meant to exist in a welding environment, it has been built for EMI protection. The unit has been successfully installed in HFI welding.

0.3 s

Yes. However the system is optical-less which is part of the patent. The specific electronic construction is under patent.

The system has a mechanical shutter and an air flow rate. Both of these adequately protect the sensor head. In HFI applications the system has been operating for 1year without any degredation in performance.

Yes the Weld QAS is pc based controller. The software has been written in C++.

1 day of production is approximately 20MB. Data that is store includes: Date/time stamp ; all measured process data, temperature profile data. The network server option allows for a back office environment to view and chart the measured data collected by the TPS system. For the back office archive system, There are several operational modes. The systems can store all data, the measured and calculated parameter as plotted curves with the thermal profile, for each tube or for each tube number or for each tube with defects. The system can also store no plotted curves and thermo profiles. In all cases, the result of quality monitoring, averaged values, weighted quality mark will be stored from every tube.

A physical install is about 1 day if the site is prepared ahead of time. The system requires a teach mode to setup the TPS unit. In total the mean onsite time is 5days.

No. The system does not alert the operator what type of weld discontinuity has occurred. What it does do is alert that the process has gone beyond the limits. The operator and QA can then review either at the mill or offline the thermal image to see the type of defect.
Experience shows that after a few days of use the operator is able to determine what the weld defect is.

Yes. There is a weighted process # that takes into account the different process inputs. This number is determined to operate in good, warning and fail limits by the user. If a limit is exceeded, an output is generated to external devices such as a light tower, paint marking system.

The administrator can setup access rights for the operator. The operator has input from a keyboard / mouse and a scroll dial on the controller.

No. The system is sold as a packaged solution.

Yes the WeldQAS controller is mandatory. The controller has been designed in such a way as to provide maximum functionality and operability with the plant, equipment and users.

NO.

Yes. There are 999 recipe or presets that can be stored. These can be recalled either by selection of the operator or via a binary code which is linked to a unique ID and recalled automatically.

WeldQAS system has standard digital inputs to get information from mill control, so that the systm can automatically load different check instructions for different tube types. Also the system has several input possibilities for order numbers, charge numbers and if the customer has signals from the mill. The easiest way is to use digital I/O but solutions have been implemented using an industrial bus. These depends from customer requirements.

The operator has two different screen views. In run time, he can view the process data on display as well as the thermal profile.

No. Not at this point.

Possible, is it possible to have a funded demo?

This is part of the patent

The maximum temperature of the unit is 1400C. It is important to point out that the system is intended as a weld quality monitoring system. Therefore the temperature plays a less important factor since what will be important is the relative change of the thermal profile to a good thermal profile. In this regard, the system is monitoring the effects of defects on the thermal field and as a result, the accurate temperature measurement becomes less important.

The measurment from the steel material with the sensor is independant of the surface in a wide range, so the emissivity is not as important for the application, its not adjustable. The unit is calibrated at the factory to a known steel material with a known emissivity. If the client would want to know exact temperature, the unit would have to be calibrated again during the installation step.

The analog port is available. At this point the system has not been integrated into a PID loop with a power source. This requires the participation of the welding power source OEM.

Yes. At this time, the system has been successfully implemented in HFI tube producing operations.

welding inspection[Jan19th , 2011]—Invisual E. Inc. is pleased to announce the offer of an in process real time thermal scanning system > as a tool for welding inspection and monitoring for continuous or batch processes. Metal Fabricators and Tube and Pipe producers are constantly managing material costs, yield, efficiency and quality to improve profitability, acquire and retain clients and mitigate liability costs. Now available, the thermal profile system provides real time in process, at the weld, weld monitoring and welding inspection detection of welding defects. The system utilizes the thermal distribution of the heat affected zone to detect irregularities of the thermal field during solidification of the welded seam.

Key Features and Benefits:

  • Real time visibility of what is happening at the weld
  • Early detection of weld defects, irregularities and process anomalies
  • Net reduction in waste and increase in quality
  • Complete traceability and production reports for audits
  • Mill or production equipment integration
  • I/O signaling, Alarm generation, production tags
welding inspection

The system is suitable for all welding processes and has been mechanically engineered for the welding environment and ingress protection.

welding inspection

Welding Defects:

  • Off seam Weld
  • Porosity
  • Burn through
  • Lack of Fusion
  • Cold Spots (Pasty Weld)
  • Lack of Penetration
  • Energy input fluctuations
  • Material variances
  • Hot Cracking
  • Asymmetric welding
Also visible at Quality Digest Magazine, PR LOG. About Invisual E. Inc. Invisual E. Inc is dedicated to advancements of quality, efficiency and capabilities for manufacturing.  A technology firm that works with OEM, integrators and manufacturers to build brands, expand markets, grow revenues.