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Ultrasonic Inspection is very slow and has a “blind” spot between the probe and 3mm into the surface. Ultrasonics can miss cracks. However, it will provide information deep into the gear cast.
An argument can be made on the relevance of finding casting imperfections:
The advantage of inspecting mill gear drives utilizing ASTM E2905 over Eddy Current, or for that matter, all other methods of NDT for gearing applications, is recorded data is utilized. ASTM E2905 is cleaner, faster, documentable, and covers a larger area in less examination time better than any other traditional Non-Destructive Testing methods today for gearing applications. Drastically reduces inspection time. Covers a large area in one single pass. Provides real-time mapping of the inspected region, facilitating data interpretation. Improves reliability and Probability of Detection (POD). Unlike some other inspection methods, this will size cracks accurately, and all of the data is electronically archived for future reference in C- Scan imagery.
The main advantage of E2905 are the 2 and 3D displays that are produced. With these types of displays, it is possible to characterize the defect.
For example, Eddy-Current gives us only a phase angle and amplitude signal that we must interpret and thus make a judgment call on the type of defect. This judgment call relies solely on the inspector. See Figure 1.
Benefits of ASTM E2905 over Magnetic Particle and Dye Penetrant for Cleaning and Inspections of Mill Gear Drives
|Preparation / Inspection Times||Magnetic Particle / Dye Penetrant||E2905|
|Cleaning||10-12 hours||1 hour|
|Inspection||20-30 hours||8 hours|
|Report||Paper||Full Electronic Backup|
|Total Time for Inspection||25 – 35 hours||8 hours|
|Compliance with ASTM E2905||No||Yes|
Much faster than traditional methods.
Provides more production revenue than using traditional methods.
All data is recorded electronically; not on paper as in Magnetic Particle or Dye Penetrant.