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Maintenance-free components for XXL X-ray scanners for product quality control

Whether cracks, fractures, inclusions, deformations or foreign objects: the Rex-Cell X-ray scanners and tomography systems from Flow Capture Germany GmbH can be used to find the smallest defects in components. Industrial companies and research institutes all over the world benefit from these systems. They buy the scanners themselves or send their products to the inspection service offered by the company in Rehden. The special feature is that the CEO of the two-member limited company builds the scanners single-handedly. To do this, he needs machine components that can be installed quickly and easily and are as maintenance-free as possible. When it comes to drive technology, he therefore relies on products from igus.

X-ray scanner from Flow Capture

Profile

  • What was needed: Drive technology for the up and down movement of the X-ray and detector unit; energy chain to protect the moving energy and data cables
  • Requirements: High service life, no lubrication and maintenance, simple control system and installation
  • Success for the customer: With our drylin linear module in customised length together with motor, control system and energy chain, Robert Klaus has a customised solution that is quick to install and easy to control. The igus components help him to keep to his tight schedule. As the linear guides do not require external lubrication, he saves time and money on maintenance.

Products used

Problem

Flow Capture Germany GmbH is a two-member team consisting of CEO Robert Klaus and his test specialist Hanna Siebel. Klaus builds the Rex-Cell X-ray scanners single-handedly, including the new, oversized L series. It can be used to X-ray large objects with a length of up to 450 centimetres, a width of 120 centimetres and a height of 180 centimetres - bulk goods, motorbikes, helicopter tail rotor blades or entire batches of hundreds of boxes of nasal spray bottles. Up to 90 euro pallets can pass through the scanner per day.

The system is housed in a lead-lined sea container measuring 6 x 2.6 x 2.6 metres and weighing around 5 tonnes. Inside, a gantry moves along the entire length of the container on a rail system. To the left and right, X-ray scanners and a detector move up and down along the gantry's supporting pillars.

For the latter, i.e. the vertical movement of the X-ray scanner and detector, Robert Klaus was looking for suitable drive technology. It had to be easy to install and require as little maintenance as possible. He was also looking for a solution for the energy and data cables moving along the rail that would protect them from cable breakage.

Solution

In dialogue with our motion plastics specialists, Robert Klaus quickly found the right components. A custom-made drylin SAW-1660 linear module with lead screw is used for the vertical movement, which guarantees smooth running despite an above-average stroke length of 1,800mm. The scanner and detector are assembled on carriages that move on an aluminium rail with a W profile. As the carriages do not run on recirculating ball rollers but on liners made of high-performance plastic with integrated solid lubricants, no external lubrication is required. This eliminates the need for maintenance for Klaus and his customers.

The drive is provided by a NEMA 24 stepper motor; in addition, a drylin D1 control system is used, which allows for quick programming of the carriage movements - via web browser on a PC, smart phone or tablet. A brushless EC/BLCD DC motor ensures the horizontal movement of the gantry.

Energy chains of the easy chain series Z16 are laid along the rail to safely guide the energy and data cables. They are very easy to fill as the cables are simply pushed in from the outside.

The simple assembly of the components and the fast programming of movement sequences help Klaus adhere to his tight schedule. Thanks to his 15 years of experience, his passion and our motion plastics, he was able to assemble the Rex-Cell L in just three weeks. He is particularly pleased that at igus small customers also receive comprehensive support and customised solutions: "For me, there is no serious alternative to igus, especially when it comes to energy chains."

“From the very first minute, igus supported me reliably with linear modules of the length I wanted, with responsive, competent service and no minimum order quantities. I was pleasantly surprised."

Robert Klaus

CEO Flow Capture Germany

X-ray scanner from Flow Capture in the container

Objects up to 4.50 metres long can pass through the material inspection in the Rex-Cell L-series X-ray scanner. The system is housed in a lead-lined container.

XXL X-ray scanner from Flow Capture

For the vertical movement of the X-ray scanner and detector, 1.80 metre long linear modules with lead screw, NEMA 24 stepper motor and drylin D1 motor control systems are used.

X-ray scanner from Flow Capture in the container

drylin SAW-1660: X-ray scanner and detector are assembled on carriages that move on an aluminium rail with W-profile and lead screw drive.

XXL X-ray scanner from Flow Capture

Well protected: The energy and data cables of the X-ray scanner move in energy chains that are easy to fill.