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Karma Innovations & Solutions Pvt. Ltd. #46, Arasamara Street, Avarampalayam, Coimbatore – 641006,
Mobile: +91-98942-57406, Land line: +91-422-2560609 E-mail ID: [email protected]
Inspection of HRC Fuses Using Digital X-ray Inspection System
HRC Fuse or High Rupturing Capacity Fuse
HRC Fuses are able to withstand and interrupt high current during short circuit. The fuse wire or
element can carry short circuit heavy current for a known time period. During this time if the fault
is removed, then it does not blow off otherwise it blows off or melts. The enclosure of HRC
Fuse is either of glass, ceramic or some other chemical compound. This enclosure is fully air tight
to avoid the effect of atmosphere on the fuse materials. The ceramic enclosure has metal end
caps on both heads, to which fusible silver wire is welded. The space within the enclosure,
surrounding the fuse wire or fuse element is completely packed with a filling powder. So, the
defect if any of the fuse element is invisible once manufactured.
Karma Innovations has the solution to find the Internal Defects of HRC Fuses using
Digital X-ray Inspection System with Quality, Convenience and Minimum Cost.
Digital X-Ray Today
The film based x-rays were in vogue for over 100 years. It required separate dark rooms,
chemicals & consumables, etc. and we can get result through hard copies (film). It consumes
much time to inspect the component.
But the Digital x-rays passing through the object are then collected and displayed in a computer
using advanced digital x-ray sensors. This is a great advancement when compared with the
film based x-ray systems.
Our Solution
Going strength for strength we have launched our Digital X-ray Inspection System Upgrade
Services. Our first customer to use this service is a multinational manufacturer of high end
industrial grade electrical fuses.
They were finding it difficult to operate their machine which they purchased earlier, as the images
were not sufficient for quick and easy decision making. The time taken for the operators to detect
the defective components and back tracking for the components removal was very straining and
hence consuming a lot of time. The sample image from the old machine is shown in Picture 1.1.
Karma Innovations & Solutions Pvt. Ltd. #46, Arasamara Street, Avarampalayam, Coimbatore – 641006,
Mobile: +91-98942-57406, Land line: +91-422-2560609 E-mail ID: [email protected]
Picture 1.1
The Advantages of the Karma Digital X-Ray System
Compared to old x-ray machine Karma’s Digital x-ray system has the following advantages:
1. We have provided with a cutting edge technology sensor that has 5 megapixels of resolution.
2. Also by adding a time saving automated loading table, up to 64 fuses per loading can be
inspected. This ensures that there is 100% Inspection of all the fuses made in a day and adds
to the operator convenience.
3. High clarity images ensure that the operator be an unskilled person. (see picture 1.2)
4. We have provided additional protective lead shielding adding to the operators’ safety.
Karma Innovations & Solutions Pvt. Ltd. #46, Arasamara Street, Avarampalayam, Coimbatore – 641006,
Mobile: +91-98942-57406, Land line: +91-422-2560609 E-mail ID: [email protected]
Picture 1.2
Image Comparison
1. The hexagonal fuse element & thin gauge filament inside the ceramic holder in Karma’s
Image (picture 1.2) has the Better Clarity. But this is not visible in the competitor’ image
(picture 1.1).
2. Pseudo coloring image (picture 1.3) shows the fuse with multicolor which helps the operator
to identify the internal defect of the fuse without any extra effort.
Karma Innovations & Solutions Pvt. Ltd. #46, Arasamara Street, Avarampalayam, Coimbatore – 641006,
Mobile: +91-98942-57406, Land line: +91-422-2560609 E-mail ID: [email protected]
Picture 1.3
Karma Innovations & Solutions Pvt Ltd’s Specialization
Karma specializes in offering custom made Digital X-Ray Inspection Systems. We have
capability to customize the following as per the customer’s needs:
1. X-Ray Source
2. X-Ray Sensor
3. Radiation Protection Safety System
4. Software for easy decision making
5. Automation to different levels based on customer needs
Karma Innovations & Solutions Pvt. Ltd. #46, Arasamara Street, Avarampalayam, Coimbatore – 641006,
Mobile: +91-98942-57406, Land line: +91-422-2560609 E-mail ID: [email protected]
Our expertise in providing automation solutions was a major strength to offer the optimum
solution to our customer. Customers Achieving Higher Effectiveness and Higher Efficiency go
with Karma’s Policy of Working Empathetically with Our Customers to Deliver the Maximum
Value.
The system also used for checking for defects such as pores, blow holes and shrinkage in
components made of different materials [aluminium, plastics, rubber and steel in automobile
industry] and detecting foreign bodies in industries such as food processing and cosmetics.
In case any need related to Digital X-Ray Inspection Systems, please feel free to mail/call us.
Karthikeyan Jawahar Director
Karma Innovations & Solutions Pvt Ltd Mobile: +91 98942-57406 E-Mail ID: [email protected]
Karma Innovations & Solutions Pvt. Ltd. #46, Arasamara Street, Avarampalayam, Coimbatore – 641006,
Mobile: +91-98942-57406, Landline: +91-422-2560609 E-mail ID: [email protected]
Inspection of Aluminium Components Using Digital X-ray Inspection System
Digital X-Ray Inspection Systems are used for checking for defects such as pores, blow holes
and shrinkage in components made of different materials [aluminium, plastics, rubber and
steel in automobile industry]. The system can also be used for detecting foreign bodies in
industries such as food processing and cosmetics.
Principle of Working
This inspection method utilizes the penetration capability of x-rays to sense for internal
defects in any component.
Most of the aluminium automobile components require a maximum material thickness of
about 50mm only. Such thickness can easily be penetrated by X-Ray generators that generate
X-Rays as and when required.
Digital X-Ray Today
The film based x-rays were in vogue for over 100 years. It required separate dark rooms,
chemicals & consumables, etc. and we can get result through hard copies (film). It consumes
much time to inspect the component.
But the Digital x-rays passing through the object are then collected and displayed in a
computer using advanced digital x-ray sensors. This is a great advancement when compared
with the film based x-ray systems.
The Advantages of Digital X-Ray System
Compare to film based X-ray system Digital X-ray system has following advantages:
1) 100% Inspection Possible. Because the time taken for the capturing the image is very
less.
2) One exposure of the image on the computer takes 0.5 seconds in Digital X-ray
Inspection. But film based x-rays takes dozens of minutes cycle time.
3) X-ray viewing in the form of Video while monitoring the component is moving with
5 degrees of freedom (X, Y, Z axes; Tilting; Rotation).
4) Being digital, the image can be modified in different ways for identifying defects.
Zooming, measuring length of defects, writing comments and analyzing number
of defects in a given region can all be done by any operator with minimal training.
5) Special software is available for advanced image processing to enhance the defects
to ensure only the best quality components reach the customer.
6) No Consumables. Does not require films, chemicals, dark rooms, etc.
These advantages lead to the most important benefit to our customers Improved Quality of Manufactured Products.
Karma Innovations & Solutions Pvt. Ltd. #46, Arasamara Street, Avarampalayam, Coimbatore – 641006,
Mobile: +91-98942-57406, Landline: +91-422-2560609 E-mail ID: [email protected]
The Digital X-ray Image below shows the defects in an aluminum component.
Picture 1.1
Picture 1.2
Karma Innovations & Solutions Pvt. Ltd. #46, Arasamara Street, Avarampalayam, Coimbatore – 641006,
Mobile: +91-98942-57406, Landline: +91-422-2560609 E-mail ID: [email protected]
Karma Innovations & Solutions Pvt Ltd’s Specialization
Karma specializes in offering custom made Digital X-Ray Inspection Systems. We have
capability to customize the following as per the customer’s needs:
1. X-Ray Source
2. X-Ray Sensor
3. Radiation Protection Safety System
4. Software for easy decision making
5. Automation to different levels based on customer needs
In case any need related to Digital X-Ray Inspection Systems, please feel free to mail/call us. Karthikeyan Jawahar Director Karma Innovations & Solutions Pvt Ltd Mobile: +91 98942-57406
E-Mail ID: [email protected]
www.karmainnovations.com