Inspection Of Metallic Parts Inside A Thick Metal Enclosure

Challenge Details

We refurbish worn out (primarily metallic) parts (sub systems) of various types of Machines/systems such as motors, hydraulic systems, transmission elements, IC engines, Prime Movers & their sub systems.

Customers are charged based on the degree of damage to the sub-system components that are to be refurbished. The inspection is carried out at our designated service centres. If the wear and tear / damage of the sub-system components is within the set norms, customers are charged at a lower rate. However, if the wear and tear is beyond the set norms customers are charged a higher amount, and in some cases wherein the components are severely damaged, no refurbishment is carried out.

Our aim is to complete the inspection as quickly as  possible. It takes typically around 24 to 48 hours to make a complete assessment of the condition of the sub-system components. The inspection is carried out by stripping down the machine/system and checking all the sub systems and the related interactions as per the guidelines.

The inspection is done visually, using gauges and specialized equipment for the specific components. Inspection is carried out to check for the following (fig 1):

1. Mechanical wear and tear
2. Any damage due to chemical reaction/attack on metallic surface
3. Thermal and shock damages
4. Internal cracks, chipping of metal
5. Increase/decrease in clearances and interference problems.

This process is labour intensive and highly dependent on the operator’s skill & experience. The inspection is, therefore very subjective and cannot be scaled up easily. In addition, the efficiency of the operator also varies throughout the day. The operators get fatigued due to continuous operation.  We are looking to modify the inspection process to improve efficiency and accuracy of inspection.

Solutions are invited that will satisfy the following criteria:

1. We should be able to inspect the sub system components for wear and tear without stripping down main system. i.e the solution should be able to scan the sub-system components which are enclosed in a thick metallic enclosure that is 5-10mm thick.
2. Perform accurate inspection very quickly, ideally in a few minutes and generate the inspection report.
3. The solution should be inexpensive as we would like to deploy it in many locations throughout the country.
4. It should not require skilled operators to operate the machine.
5. It should be a standalone system and flexible enough to inspect various types/configurations of machines/setups.