FlawExplorer Sensor

Figure 1 – FlawExplorer Laser Shearography sensor with short-wave halogen thermal excitation presenting an Istra4D phase-map image of a composite overwrapped GFRP pressure vessel from Automotive NDT. The phase display presents two indications of ply wrinkling within the overwrap.

The FlawExplorer is a laser shearography NDT sensor designed to be used for post-production quality control applications or in-field (in-service) component inspections. Depending on the application, the sensor can be configured with thermal or vacuum (partial) excitation systems and may also be automated. It incorporates the very latest in phase-shifting technology delivering accurate and reliable measurement results through clear and sharp imaging with sub-micrometer displacement resolution.

The FlawExplorer sensor is completely contained in one, lightweight (5 kgs / 11 lbs) unit. Only two connections are required to operate the sensor; one for power and one for camera data. With fully integrated imaging & control electronics, the sensor incorporates; a (standard) 3.2 MPx or (optional) 5 MPx, CMOS camera with a maximum frame rate of 37 & 24 Hz, respectively, a varifocal zoom lens, eight (Class 3R) laser diodes, automatic shearing, automatic projection calibration, and phase-shifting piezos. The sensor is contained in an aluminum housing with a detachable safe-guard ring, the rugged design of the FlawExplorer is designed to withstand shocks, knocks, and vibrations.

Laser Shearography has one of the highest inspection rates compared to any NDT method, specifically because it utilizes a large Field-of-View (FoV) from the use of multiple coherent laser diodes.
A FlawExplorer uses 8 laser diodes to generate a large illumination area = Field-of-View (FoV). For a standard 3.2 MPx camera, the achievable projected image size in one shot can be up to 2.9 m x 2.1 m (9.4 ft x 7.0 ft) or for an optional 5.0 MPx camera, up to 3.4 m x 2.8 m (11.2 ft x 9.3 ft) The inspection speed of the FlawExplorer is unmatched compared to any other NDT technique, delivering high throughput rates for time-saving inspections.

A FlawExplorer system can be completely automated, including camera and heat triggering, display settings, filters, and control parameters. Whether mounted on a robotic arm, linear traverse, or an XY gantry, the sensor uses a dedicated communication protocol allowing complete interaction between the FlawExplorer software, Istra4D, and an autonomous PLC interface. Numerous successful automation projects for diverse NDT applications of Laser Shearography have driven the normalized requirement for robotic integration. This possibility is now available as a standard software module option, for complete reproducible testing.

Istra4D, Dantec Dynamics’ advanced laser shearography software, is intuitive and simple to use. With a clear user workflow, users have easy control of all relevant measurement configuration parameters, including; brightness, shearing, projection, and visualization settings. Users can easily perform real-time measurements and also advanced post-processing analysis of acquired results. Whatever the NDT application, Istra4D is the imaging workhorse behind all of Dantec’s laser shearography systems.

Components

Vacuum (Partial) Excitation

Vacuum (Partial) Excitation

Vacuum (partial) excitation involves the application of a change in pressure within an entrapped volume of air between a surface section and a vacuum hood frame
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Thermal Excitation

Thermal Excitation

Thermal excitation involves the application of heat to the surface of a structure through the use of heat lamps. When heat is applied to an object, the temperature increases and surface starts to swell and expand
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Laser Shearography User Training

Laser Shearography User Training

This course is provided on our eLearning platform and consists of four learning modules, complete with documentation, videos, tutorials, charts and quizzes
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