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Ultraheli testmasinale immersioonvanni prototüüpimine

Bachman, Rainer (2019) Ultraheli testmasinale immersioonvanni prototüüpimine. [thesis] [en] Prototyping an Immersion Tank for Ultrasonic Test Machine.

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Abstract

Käesoleva töö eesmärgiks oli luua immersioontestmasinale vann ning teada saada, millistel tingimustel saab õige näidu. Töö käigus tuli lõputöö autoril olla pidevas koostöös NDT spetsialistidega, et luua vannile õige disan ja parim lahendus. Vanni loomise eesmärk oli kulude kokkuhoid – täisautomaatse masina soetamine maksaks 46 520 (USD), ise valmistatud vanni koguhinnaks kujunes 70,94€. Vann valmistati kasutades pleksiklaasi (vanni kest), polüatsetaali (kinnitusplaat), roostevaba terast (keermelatt ja liblikmutter) ja alumiiniumsulamit (nurgik keermelati stabiliseerimiseks). Kesta seinad kinnitati liimiga ning vahed täideti silikooniga. Keermelatt ja liblikmutter kinnitati keevisega ning nurgik kinnitati vanni külge neetide abil. Töö käigus valminud vanniga tehti kaks katset. Esimese eksperdimendi käigus asetati polt pooleldi vee alla ning paigutati sondist võrdlemisi kaugele. Ultrahelimasina ekraanile ilmunud tulemuselt oli näha, et polt oli defektiga, mis oli tõsi, kuid terve poldi vette asetades tuli sama tulem. Vale näit tekkis, sest ultraheli pendeldas sondi ja poldi vahel, mistõttu tekkis ekraanile veateade. Enne teist katset tehti vannile modifikatsioon – lisati üks sein, et vanni mahtu suurendada. Mahu suurendamise eesmärgiks oli uputada polt üleni vee alla. Lisaks asetati polt uuel katsel sondile tunduvalt lähemale, et ei tekiks pendeldust. Positiivne tulemus saadi seadeldise teisel katsel, kui ultrahelimasinale ilmusid õiged näidud. Prototüübi loomise võib lugeda edukaks, kuid õige vanni valmistamisel tuleb silmas pidada järgnevat: • Kõik puurimised, lõiked ja kinnitused tuleb teha väga täpselt – iga eksitud millimeeter hakkab katsetulemusi mõjutama. • Eduka tulemuse saamiseks peab katsekeha olema täielikult vee all. • Poldi ja sondi vahe minimaalne – mida väiksem distants, seda vähem mõjutab vee liikumine katse tulemust. Töö käigus omandas lõputöö autor palju uusi teadmisi NDT olemuse kohta, sai veidike aimu milline on tootearendaja töö - kurbus läbikukkunud soorituse korral ning rõõm eduka testi korral. Lisaks mõistis töö autor ajakulu, mis läheb ühe väikse toote väljatöötamisele. Prototüüpvanni loomise ning katsetamiste käigus saadud info põhjal luuakse uus vann. Uue vanni valmistamiseks kasutatakse 3D printimist, et välistada lekkimisohtu, puurimise ja lõikamisega tekkinud vigu ning saada visuaalselt ilusam vann.

Abstract [en]

The main aim of this thesis was to create a tank for ultrasonic immesrsion test machine and to find out how to get the right reading from the test. During the process the author of this thesis had to be in constant cooperation with NDT personnel in order to find the right desing and best solution for the tank. The main reason for creating this tank was to cut expenses – fully automatic ultrasonic immersion test machine would have cost 46 520 (USD), but self-made tank cost only 70,94€. The tank was built using plexiglass (tank body), polyacetal (fixing plate), stainless steel (threaded rod and wing nut) and aluminium (angle to stabilize the threaded rod). Tank body was fixed with glue and gaps were filled with silicone. Threaded rod and wing nut were welded together. Angle was riveted to tank body. Two testings were carried out for the tank. During the first try only half of the bolt was underwater, it was also quite far from the probe. Ultrasonic machine showed that the bolt was cracked which was true. When technicians placed proper bolt to the tank same results occured, therefore some modifications were made. Before second testing an additional wall was added to the tank to increase the capasity. The reason for increasing was to place the whole bolt underwater. Bolt was also placed closer to the probe. Positive result was achieved during second attempt, when the ultrasonic machine showed the right readings. Prototyping of this tank can be considered successful but there are certain things that should be kept in mind when building a proper tank: • All drillings, cuts and fastenings have to be precise – every mistaken millimeter will have an effect on the results. • For a successful test, the bolt should be fully underwater. The distance between bolt and probe should be minimal – water movement won’t effect results that much. During the process the author of this thesis got a lot of new knowledge about nondestructive testing and got a little hint of product developer’s work – sadness when the tests fail and the joy when results are positive. Also about how time consuming it can be to create a small product. New tank will be built using the info which was gathered during building and testing of the prototype tank. 3D printing will be used to create the new tank. This will prevent the tank from leaking and also mistakes made while drilling or cutting material will be avoided.

Item Type: thesis
Advisor: Annika Koitmäe-Pihl
Subjects: Mechanical Engineering > Production Development > Industrial Design
Divisions: Institute of Circular Economy and Technology > Industrial Technology and Marketing
Depositing User: Rainer Bachman
Date Deposited: 06 Jun 2019 07:36
Last Modified: 06 Jun 2019 07:36
URI: http://eprints.tktk.ee/id/eprint/4311

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