Operation

Inspection and condition monitoring of products in the utilization phase

Operation

Product inspection or condition monitoring during the utilization phase

In the field of inspection and monitoring of structures during operation or maintenance, Fraunhofer IZFP focuses on the development of nondestructive methods and procedures for condition monitoring and condition assessment, including lifecycle management. These activities range from processes for component and parts maintenance, to complete monitoring systems for condition-based inspection applications.

In this area, researchers evaluate various NDT technologies such as ultrasound, electromagnetics, eddy current, microwave, thermography and combinations thereof (multimodal NDT). Using these technologies as a foundation, inspection concepts, laboratory samples and prototypes are developed for applications in the automotive, railway, aerospace, energy technology and infrastructure industries.

Challenges in the field of Service / Maintenance will increasingly shift towards condition-based maintenance in the sense of "predictive maintenance," where NDT-based condition monitoring will be an essential part of the value chain. Much of this research focuses on quantitative ultrasound inspection systems. In this context, EMAT (electromagnetically excited ultrasound transducer) is of special interest for guided waves, while ultrasound-based sampling phased array is of special interest for three-dimensional image processing.

These methods are used for various inspection-related issues in the maintenance and diagnostics of safety-relevant components, such as for railway (wheel set inspection), infrastructure (concrete inspection) and plant (pipeline inspection) systems. With this in mind, the institute carries out diverse R&D activities that focus on the development of new reconstruction and image processing algorithms for data evaluation and data visualization. This also applies to the combination of multiple NDT methods for multi-modal inspection applications. An important trend here is the entire field of condition monitoring, which involves permanent monitoring with the goal of optimized resource efficiency and/or for assessing the safety margins of components or operational systems. This field is becoming increasingly important not only in the energy (nuclear power plants et al.) and aerospace sectors, but also in the railway, infrastructure and plant industries. The development of a multi-modal sensor platform with specific sensor technology and data analysis is at the forefront of current research activities.

 

Keywords

Condition Monitoring, Lifecycle Management, Controling

BetoFlux: Portable Magnetic Flux Leakage Inspection System for ­Detecting Corrosion Damage in Prestressed Concrete Poles

© Photo BauConsulting Dr. Walther

Magnetic flux leakage inspection

Intuitive representation of the location and condition of ferromagnetic prestressing steel

Specifically designed for portable use

Easily adapted to different concrete pole diameters

Less effort compared to alternative inspection methods such as X-ray

Minimal risk of additional pole damage

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Thermographic System for Condition Monitoring

© Photo Fraunhofer IZFP

Cognitive thermographic monitoring system

Exchangeable camera module (320x240 Pixel with 60 Hz)

Self-sufficient and autonomous measuring system

Supervisions of “ Regions of Interest“

Suitable in multimodal sensor platforms:
Different measurement methods can be combined
Fusion of the results (thermography, ultrasound, eddy current)

MoniDAQ: Self-Sufficient Platform for Permanent Condition Monitoring of Infrastructure Constructions

© Photo Katharina Wieland Müller- Pixelio

MoniDAQ: Modular, energy self-sufficient board providing eddy current inspection, inclination measurement, magnetic flux leakage inspec­tion, ultrasonic inspection, etc. and recording all sampled data over long periods of time while dissipating extremely low amounts of energy

Self-sufficient and eco-friendly power supply by integrated photovoltaic cell

Maintenance-free long-term operation

Supersensitive defect detection

Telemetric data recovery by radio-controlled interface

Low costs per unit

Unique combination of Fraunhofer IZFP‘s proven nondestructive sensor technology

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BetoScan: Robot Platform for NDT Sensors

© Photo Fraunhofer IZFP / Uwe Bellhäuser

BetoScan

Autonomous, self-navigating robot platform designed for NDT sensors

For inspecting several hundred square meters of concrete parking decks per day in high resolution (single-person operation)

Autonomous operation over obstacle-free surfaces using a pre-defined pattern

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UER III: System for Ultrasonic Stress Measurement in the Rim of Railroad Wheels

© Photo Fraunhofer IZFP / Uwe Bellhäuser

UER III: System for ultrasonic stress measurement in the rim of railroad wheels

Heavy/operational maintenance

Wheel production (according to DIN EN13262) / wheel development

Digital data transmission between manipulator and operating unit

New miniaturized in-house developed ultrasound electronics for manipulator frontend

Frontend solution in order to minimize electromagnetic interferences

Software with various options for documentation

3 alternative setups: Stationary pillar, stationary swivel arm, mobile workshop trolley

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