In an ultrasonic inspection system for the aerospace industry, carbon components are examined for cracks and material defects using a water jet. The osmosis water used serves as the transmission medium for the ultrasound. The objective was a precisely controllable, space-saving valve solution that can be integrated into a 5-axis motion and reliably covers the required range of flow control.
At a glance
- Industry: Aerospace industry
- Application: Ultrasonic testing of carbon components
- Medium / process: osmosis water as ultrasonic carrier medium
- Challenge: Precise flow control with limited installation space and moving axis kinematics
- STASTO solution: Customized sliding gate control valve design with separate functional unit and externally mounted positioner
- Result: Precise bandwidth control with compact, integrable valve technology
The challenge
In the aviation industry, carbon components are tested for structural defects using ultrasonic methods. Osmosis water is used as the coupling medium for the ultrasound, and its volumetric flow must be precisely controllable over a wide range.
The system operates with 5-axis motion, which makes installation space and weight a central factor. At the same time, the test process requires a stable and reproducible control characteristic. Fluctuations in flow can directly affect the quality of the measurement results.
Standard valves with conventional actuators proved to be not sufficiently suitable, as they either exceeded the available installation space or were unable to ensure the required control accuracy across the entire range. In addition, the solution had to be maintenance-friendly and integrable into the existing control concept.
The STASTO solution
A specially adapted sliding gate control valve was used, which was precisely matched to the process conditions. For precise control, a separate version of the functional unit was selected, allowing the valve to be optimally adjusted to the required operating parameters.
The positioner was not mounted directly on the valve due to space constraints, but on a wall bracket. This design enabled compact integration into the moving axis structure of the system.
Through design modifications, the valve could be positioned in a favorable control ratio even with very limited installation space. This made it possible to cover the entire required control range with just one valve unit.
The solution was developed in close coordination with the machine builder. The main focus was on the mechanical integration, the connection to the existing control system, and ensuring reproducible control parameters.
The result
The specific adaptation of the valve enabled stable and precise flow control across the entire range.
The compact design supports integration into moving axis systems and contributes to a clearly structured plant architecture. In addition, the external mounting of the positioner improves accessibility for service and adjustment.
In continuous operation, the solution ensures high process stability and supports reproducible quality of the ultrasonic testing. At the same time, the integration effort for the machine builder is reduced.
Added value for machine builders
- Compact valve technology for confined installation spaces
- Exact control characteristic over a wide range
- Flexible mounting options for actuator and positioner
- Good integration into existing control and automation concepts
- Reduced coordination effort through an adapted system solution
This solution is particularly suitable for
- Ultrasonic testing systems
- Non-destructive testing methods
- 5-axis machining or testing systems
- Systems with limited installation space
- Processes with precise water or fluid control
Contact
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