Fox-IQ On-line XRF Tube & Rod Analysis System Webinar
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Free webinar available: http://bit.ly/1ux16UE FOX-IQ XRF System product details: http://bit.ly/1kDXMUy Whether your company manufactures alloy components for chemical plant processes, surgical implants, or the aerospace industry, attend this webinar to learn about an automated, non-destructive and cost effective way to achieve greater quality control efficiency and achieve 100% quality control for alloy based materials. Join Ken Smith from Olympus in this discussion to learn about the FOX IQ On-Line XRF system and how to achieve 100% grade chemistry QC. This live, 30 minute webinar presentation will review the latest technology and cover key aspects of how to evaluate production efficiency for QC and PMI. Contact us: http://bit.ly/1rDmq94 Sign up for our Newsletter: http://bit.ly/1j5FOTy
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Fox-IQ On-line XRF Tube & Rod Analysis System Webinar
- 1. Fox-IQ On-line XRFFox-IQ On-line XRF Tube & Rod Analysis SystemTube & Rod Analysis System • Ken Smith, Global Business Development • May 8, 2014
- 2. Today’s Discussion Topics • “I thought Olympus made cameras…” • Field & Industrial Instrumentation Overview • X-Ray Fluorescence (XRF) for Alloy Analysis • Automated XRF QC & Sorting Technologies Olympus Scientific Solutions Americas
- 4. Medical & Surgical Olympus offers solutions for: •Gastroenterology •Gynecology •ENT •Pulmonology •Surgery •Urology
- 5. Industry SolutionsOlympus provides solutions for a variety of industries
- 6. Weld Inspection Solutions Corrosion Inspection Solutions Composite Inspection Solutions Tube Inspection Solutions Industrial Scanners Advanced NDT Solutions
- 7. Tube Inspection Systems In-Line/Off-Line ERW Tube Inspection System FOX-IQ Process & On-line XRF System Rotating Tube & Bar Inspection Systems Integrated Inspection Systems
- 8. Handheld XRF Analyzers Mobile XRF Analyzers Specialized XRF Workstations Mobile & Benchtop XRD Process & On-Line XRF FOX-IQ Process & On-Line XRF System Automated XRF for Sorting and Recycling Analytical Instruments
- 9. Meatballs: Removal of copper from ferrous streams Glass: Removal of Titanium, Zirconium, and Lead from Glass cullet streams Zorba: Removal of copper and copper alloys from “heavies” stream & Purification of Aluminum and Stainless Steels from “lights” stream Automated XRF for Sorting and Recycling X-STREAM Applications:
- 10. Process & On-Line XRF Analyze Liquids & Fluids in Real Time Quickly Analyze & Compare Alloy Tubes & Rods to Grade Specs On-line XRF Systems
- 11. HH XRF for Point & Shoot Alloy Analysis
- 12. 1. X-ray tube emits x-rays XRF Theory
- 13. 2. X-rays “light up” sample, exciting atoms that return x-rays Ni Fe Cr Mo Test Sample XRF Theory
- 14. 3. Detector captures (counts) returning X-rays as an energy spectrum XRF Theory
- 15. 4. Optimized Algorithm turns spectrum into concentration (percent by mass) XRF Theory
- 16. Peak Area - Background Corrections = Net Area Net Area x Calibration Factors = Elemental % or PPM How are XRF Results Calculated?
- 17. XRF is a statistical method Ni Fe Cr Mo Test Sample Up to 100,000 photons/second Up to 100,000 photons/second
- 18. Surface Space is Critical ≈ 10 μm Penetration in Iron Alloy Matrix
- 19. Detect P to Pu With On-Line XRF
- 20. What’s on your surface? Coatings & Platings Sand-blasting (Residual Si) Shot-blasting (residual from iron pellets) Metallic dust
- 21. Sample PresentationSample Presentation Precise sample movement to and from the FOX IQ analysis window is key for: –Successful material analysis –Cost effective integration into a manufacturing process
- 23. Fox IQ Tube & Rod Analyzer PLC •Start / Stop •Interlocks PC & Peripherals Analytical SW RS-232 RS-485 Up to 30 m Up to 30 m Up to 30 m What am I pointing to?
- 24. Tube & Rod VideoTube & Rod Video
- 25. Small Samples - Wire Samples < 1 mm
- 26. Control Communication • Level 1 Analog • Between the PLC&Fox IQ Controller – Dry contacts – able to accept any voltage from you PLC; – Signals Controlled: • Input # 1: Start Test • Input # 2: Safety Interlock • Output # 1: Pass/Fail • Output # 2: Status/Busy • Output # 3: Tube Active (radiation present)
- 27. Control Communication • Level 2: Digital • Between the PLC APIFox IQ PC SW – What is an API (Application Program Interface)? • Software Utility that allows an external system to control the Fox IQ through PC Software • Host Software (supplied by OIX) will control Fox IQ hardware • Client Software (customer developed) links the PLC or another onsite computer to the Host Software using a defined set of commands provided by OIX
- 28. Application Statement Analytical & Installation Details • Analytical Goal(s) – Pass/Fail – Alloy Grade ID – Detailed Material Chemistry – Key elements, concentrations or tolerances • Output Requirements? – Voltage – Digital – Printer – Display • Site Details? – Location Floor Plan – Process Schematics • Anything else you want us to know (temp, RFI, vibration? Other?)
- 29. Calculator of Net Gain Per Month Meatballs Shredder Output (TPH): 100 Operational Hours (per mo): 240 Monthly Output (tons): 24,000 Ferrous Shred (tons): 16,320 Value added per ton: $7.00 Net increase/mo from Shred: 114,240.00$ Savings on Manual Labor/mo: 10,000.00$ Increase in Cu Extraction (%): 0.08 Extra Cu pulled (tons per mo): 13 Value of Cu Extract (per ton): $760.00 Value of incremental Cu Extract/mo: 9,922.56$ Grand Total Net: 134,162.56$ Economic Test Win Win Win
- 30. Alloy Grade Library Two Methods for Identifying Alloys 1.Fingerprint Method: Simple comparison to a reference material • Works best when: • The total number of grades handled is low (less than 10 is best) • The grades are not similar 1.Grade Specification How Does a Grade Library Work? • What does the Match # Accomplish? • How is it calculated? • How does the Tramp Element Library Help? • What are nominal values?
- 31. Chemistry is measured first • What is this material? Grade Matching is a secondary function. • Convenient for the user Grade Matching is always, ALWAYS RELATIVE • Grade Matching identifies the best match in the active library. • The value of the grade match is extended by: » Directly comparing/displaying the measurement relative to the library specification » Showing the 2 nearest matches Grade Matching
- 32. Required vs Tolerated vs Unspecified • Required Elements – What the manufacturer and the user zero in on – These elements and concentrations define the material properties, function and value – Typically 95+% of the alloy • Tolerated Elements – Not required in any way – They are expected and tolerated as long as they are less than the max allowed – Typically < 5% of the alloy • Unspecified or “Tramp” Elements – Typically, the 0.05 to 0.5% that shows up as an “unnamed” or “non-specified” – Commonly referred to as “tramp material” – This small percentage of unspecified or “tramp” material is tolerated for most applications
- 34. Measure Screen Ready for testing after successful standardization
- 35. Thank you for reviewing this info! • Please contact us: • Ken.Smith@OlympusNDT.com • www.olympus-ims.com Thank you for joining us! Questions?
Editor's Notes
- My name is Ken Smith and I want to welcome you and thank you for joining today&apos;s discussion.
- – Olympus does make cameras. And, they make a wide range of optical based technologies for research, medical, and industrial testing. We will spend 5 minutes or so giving you a little background on Olympus Scientific Ssolutions Americas; - The balance of the time will be spent discussing how XRF Analysis can be applied as a quality control step for the manufacture of Alloy based materials.
- Olympus continues to innovate products and technologies that expand the boundaries of digital photography and audio capture.
- Olympus’s optical techology provides tools supporting less invasive procedures, innovative diagnostic and therapeutic endoscopy and early stage cancer evaluation and treatments
- As you look at the industries cited by this slide, it is clear that the ability to make a direct and non destructive measurement of alloy grade and chemistry is a common requirement
- Olympus extends the typical range of NDT technologies by using an array technique to speed and stream-line and enhance the utility of testing devices. Combining instruments, probes, software, and scanners a more complete application solution is delivered.
- Both HH & Automated, EC -surface UT – internal flaws & XRF
- The Analytical X-ray technologies were brought into Olympus with the Purchase of Innov-X Systems & In-Xitu Technologies in 2010. In-Xitu manufactured an innovative X-ray diffraction system for doing crystaline structure based material composition analysis. The small size and rapid through-put of this technology makes it valuable for minerology and corrosion analysis using dry powder samples. On the other hand, X-ray flourescence (XRF) is most commonly used as a hand held device for alloy analysis.
- And, it is this success in the field that has brought many customers to us asking for a way to use XRF in a fully automated manufacturing process. This slide refers to on-line conveyor belt based X-ray sorting systems that allow the processing of 15 to 150 tons per hour of material. Pulling copper out of ferrous shred streams and sorting undesirable material out of a glass recycling stream are the most common applications.
- So, the Fox IQ System is a part of this family of non-destructive industrial testing technologies. Today’s discussion focuses on the Fox IQ system for QC Testing of Tube and Rod type alloy materials.
- In theory very simple: X-rays created by tube in analyzer – hit sample – sample elements fluoresce and send x-rays back – we detect and count – then do math to get concentration.
- In theory very simple: X-rays created by tube in analyzer – hit sample – sample elements fluoresce and send x-rays back – we detect and count – then do math to get concentration.
- In theory very simple: X-rays created by tube in analyzer – hit sample – sample elements fluoresce and send x-rays back – we detect and count – then do math to get concentration.
- In theory very simple: X-rays created by tube in analyzer – hit sample – sample elements fluoresce and send x-rays back – we detect and count – then do math to get concentration.
- The detector counts the number of X-rays emitted by specific energy ranges, resulting in a spectrum. Each peak represents a unique element.
- Every element has a unique and known X-ray fluorescence. The detector can detect elements P-Pu, 20+ different elements simultaneously, and how much of any element is present in the sample.
- Of course, I move the line to P, and they ask about Si.
- Grinding or cleaning is required for: Coatings, Platings, Residual paint Scale, oxide layer, metal dust, Shot-blasting (residual from iron pellets) & sand blasting may require surface preparation as well. However, for the vast majority of our nearly 100 installations, no systematic surface prep is required.
- Almost anything which can be done with the Olympus Innov-X Delta handheld analyzer can be done with the Fox-IQ. The primary challenge is the sample presentation.