FPI Inspection Basket for Turbine Fan Segments:
Our customer manufactures jet engines and they needed baskets to hold their parts through a new FPI work cell (Fluorescent penetrant inspection) that cleans the parts and applies penetrating dye to reveal any imperfections or cracks.
Our customer was developing a semi-automated work cell to 100% FPI inspect turbine fan segments before final assembly into jet engines. The work cell has a U-shaped conveyor to move baskets loaded with parts through several stations. The first station is an aqueous wash station to clean away any manufacturing dirt or debris. The next work cell station dips the basket full of parts into a tank of penetrating dye. The third station along the conveyor is an air blow off chamber that removes the excess dye from the part’s smooth surfaces, leaving dye only in the cracks or imperfections. The final station in the work cell is an enclosed booth where the parts are inspected under ultraviolet light. Any cracks hold the dye which glows brightly under the ultraviolet light. If the parts pass inspection, the basket of parts leave the inspection booth for a second pass through the wash cycle to remove any dye residue. If any parts fail inspection, the parts exit the inspection booth on a different conveyor to be reworked or scrapped. The U-shaped layout of the conveyor brings the finished parts back to the starting point so a single operator can both load and unload the conveyor.
Properly designed baskets for FPI Baskets must hold parts in a very specific orientation so the dye coats the surfaces evenly and completely. Good FPI basket designs also must have the absolute minimum of points contacting the parts, and the basket itself must a minimum of joints, both of which will trap extra penetrating dye and give false inspection readings. Our custom basket design accomplished all of these design requirements. The baskets have internal grids that locate the arc-shaped parts securely with only four small areas contacting the parts. The overall basket design is very open to allow extra dye to shed away. Even the text on the identification tags have the letters laser cut through, not stamped or engraved which would trap unwanted dye. Finally, the entire basket is powder coated with Black Nylon 11 to protect the surfaces of the parts from scratching and to bridge any small crevices between the rods that would catch dye.
Design Features shown here that could be Ideas for your Custom Basket:
- Bottom Feature: These baskets have a very smooth flat bottom face to move along a conveyor without binding. See other Bottom Feature Options.
- Surface Finish: These inspection baskets are powder coated with Black Nylon 11 to protect the parts from scratches. See other Baskets with a Surface Finish.
- Internal Grids: Internal Crossing grid rods locate and separate parts with almost no blockage of spray, drying or drainage. See other Baskets with Grids.
- Part Cradling: These parts are being cradled in a very specific orientation. See other Baskets with Part-specific Cradling.
- Basket for Inspecting Parts: The custom baskets include all the important design features optimize FPI Inspection. See other Baskets for Inspection.
- Basket used in Aerospace Companies: Aerospace manufacturers require the highest level of quality. See other Baskets used by Aerospace Companies.
- Basket used in Ramco Parts Washing Equipment: See other Baskets used in Ramco Equipment.