Rafter Equipment Corporation is the exclusive North American system integrator for HKS-Prozesstechnik GmbH (www.hks-prozesstechnik.de) and their patented ThermoProfilScanner (TPS) non-destructive weld seam inspection system. The TPS uses a unique “glassless optic” thermal imaging sensor (i.e., infrared thermography) to capture the heat profile of the weld seam just after welding. The sensor scans the weld seam 400 times per second.

The heat profile is recorded and displayed on the “Weld Quality Assurance System” or WeldQAS operator’s station. Weld defects caused by “pin holes”, “flashovers”, misaligned strip edges, excessive heat, insufficient heat, and asymmetric heat penetration are all quickly detected. Recipes for various products can be established based on known thresholds for temperature distribution across the seam, profile symmetry, profile position (i.e., on or off center), and maximum temperature. The TPS system can be used in place of typical Eddy current pin hole detection and pyrometer based weld monitoring solutions. The TPS performs these functions and much more.

The measured heat profiles are stored in a database relative to the location within a given part (i.e., tube or welded section) as determined by the customer’s existing mill speed input and cutoff signals. The individual cut parts are identified and numbered in the database. Additional parameters such as welding speed and welding power can also be recorded.

The robust TPS sensor features positive air pressurized housing that is also used to actuate the sensor shutter. If pressure is lost or turned off, the shutter automatically closes to protect the sensor. In addition, the sensor housing can be water-cooled for protection in even the harshest welding environments.

The entire historical database can be accessed and backed up to the customer’s existing network via an Ethernet connection. Profiles for individual parts can be recalled at any time for further inspection making this system ideal for ISO requirements. The TPS system has been successfully installed on both TIG welding and high-frequency induction welding mills. Future development will bring this technology to laser welding mills as well. Please contact the Rafter sales department for further information.