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Welding inspection systems

FOR PIPES

What is WELDAN? Weldan is a welding inspection system suitable to inspect the welding quality on metal pipes of small diameter; it is an online system, so its analisys is performed during the pipe forming process without interfering with the process itself. The system provides, immediately after the welding process during the forming of the pipe, the quality of the welding. It helps line operators to identify defects on the formed pipe, and automatically check-out and validate the welding process. Pipes breaks are mainly attributable to inefficient welds. The control is performed after the welding process, so when the pipe is still hot.

WELDAN is unique
WELDAN is a unique system in the Industry. Existing systems like PEC (Pulsed Eddy Current) , magnetic, or visual can identify a surface defect, but not an inner defect. It is an innovative equipment which will add a lot of possibilities to your standard way of work.

The system has been designed for metals, and it is widely used on steel pipes. The system can work as a standalone unit, and due to reduced dimensions it can be easily incorporated on a wide range of existing process lines. The installation of WELDAN will minimize troubles due to non conformity. The system is based on a micro-focus X-ray source and a high speed Time-Delay-Integration (TDI) camera and provides a real-time analysis on weld during the pipe forming process.

Weak weldings and bead evaluation
A weak welding is a potential source of troubles for the process, not only for the quality of the final product, but mainly for the process itself. Strip breakages, for example, are a big issue for operator's safety and the 75% of strip breakages, on pickling lines, are caused by a weak welding. Defects in welding process are very small and require a magnification to enlarge the vision for data analysis, using a standard X-Ray source the contours of elements appear blur and the recognition is quite difficult. Using a microfocus technology with a very small spot size, it is possible to obtain the best image resolution and defects magnification, in order to identify unconformities.

  • BEAD HEIGHT
  • BEAD WIDTH
  • BEAD RATIO
  • MISMATCH
  • DEFECT
  • HOLE DETECTION

Additionally to the welding bead measurements the system provides the overall quality and hole detection near the welding bead (e.g. Malformed edge, hole in the strip, occlusions).

Data Analisys The real-time images captured from TDI camera are submitted to a high-performances data analysis processor that uses image processing and shape recognition algorithms to measure the bead of the weld and the presence of defect. Finally, the results are showed to operator that can immediately check if the welding system is working properly. All measures can be delivered to the plant automation using analog output, hardwired digital output and/or via digital protocols. For best accuracy the system can receive line setup from Plant automation/PLC/upper levels (line speed, material thickness, etc) through protocol or manually by operator's HMI. The system can works also in full automatic mode without any settings, in this case the accuracy of recognized shape of hole / defect can be lower. The analysis of the welding can be performed when the welder is going forward (during welding process) or backward (when the welder goes to home position). Backward scan mode is preferred for thick material where an accurate analysis require a lower scanning speed.

About WELDAN development

WELDAN is in constant development! We are daily improving its capabilities. Since we have received numerous expressions of interest in our online welding inspection system over the past year. WELDAN is a system born from the request of one of our long-standing customers. The possibilities of the WELDAN system are many more than those currently implemented, and therefore is in continuous development on our part. If you are a production line owner and would like to have control on your line, contact us! We need to test our system on as many lines as possible, and we could find a formula to install the system at no cost with you.